Shaped compositions for uniform delivery of a functional agent

ABSTRACT

Shaped compositions are provided for use in delivering a substantially uniform concentration of a functional agent (e.g., an antimicrobial sanitizing agent) to a flowing stream of water. The composition may be shaped and sized to be inserted into a device configured to be attached over the end of a faucet. The shaped composition may include at least two different regions (e.g., layers). A dissolvable region includes a functional agent (e.g., an anti-microbial sanitizing agent). A substantially non-dissolvable region is disposed adjacent to the dissolvable region (e.g., adjacent the bottom surface) so as to cover a bottom surface of the dissolvable region. The geometry of the shaped composition, as well as the presence of the substantially non-dissolvable region aids in providing a substantially uniform concentration of functional agent throughout the life of the dissolvable region.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/472,442, filed Apr. 6, 2011 entitled SHAPEDCOMPOSITIONS FOR UNIFORM DELIVERY OF A FUNCTIONAL AGENT and U.S.Provisional Patent Application No. 61/472,423, also filed Apr. 6, 2011entitled FAUCET MOUNTABLE WATER CONDITIONING DEVICE, the disclosures ofeach of which are incorporated herein in their entirety.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to shaped compositions for use indelivering a functional agent into a stream of water at a substantiallyuniform, desired concentration.

2. Background and Relevant Art

In many areas of the world, particularly rapidly developing countries,the safety of the food supply is often questionable. For example,fruits, vegetables, meats, and other foods may sometimes includebacterial or other microbial carriers of infection. Such issues ofmicrobial contamination are particularly an issue in developingcountries such as China and those of Latin America. Even withinrelatively well developed countries, such as the United States and manyEuropean countries, there are occasional incidents of produce or otherfood products found to be contaminated with E. coli or other microbes.

Consumers are often instructed to wash produce and other food productsbefore consumption, although many consumers sometimes forget to do so,or even if such washing is performed, residual microbes or othercontaminants may remain on the product. As a result, food borne illnessmay still occur. As such, there is a continuing need for improvedmethods and systems for sanitizing food products.

BRIEF SUMMARY OF THE INVENTION

In accordance with the above objects and those that will be mentionedand will become apparent below, one aspect of the invention is a solidshaped composition for use in delivering a substantially uniformconcentration of a hypochlorite anti-microbial sanitizing agent to aflowing stream of water, the shaped composition comprising: a firstregion comprising a hypochlorite salt selected from the group consistingof calcium hypochlorite, magnesium hypochlorite and mixtures thereof,the first region being dissolvable into a flowing stream of water; thefirst region being substantially cylindrical so as to include a topsurface, a bottom surface, and a peripheral surface; and a second regioncomprising a substantially non-dissolvable material, the second regionbeing adjacent to at least one of the top or bottom surface of the firstregion; and wherein the first region and the second region are noteffervescent; and wherein the first region and the second region containno sodium hypochlorite or lithium hypochlorite.

In accordance with the above objects and those that will be mentionedand will become apparent below, one aspect of the invention is a solidcylindrically shaped composition for use in delivering a substantiallyuniform concentration of a hypochlorite anti-microbial sanitizing agentto a flowing stream of water, the shaped composition comprising: a firstlayer consisting essentially of a hypochlorite salt selected from thegroup consisting of calcium hypochlorite, magnesium hypochlorite andmixtures thereof, the first layer being dissolvable into a flowingstream of water; the first layer being substantially cylindrical so asto include a top surface, a bottom surface, and a peripheral surface; asecond layer consisting essentially of a substantially non-dissolvablematerial selected from the group consisting of cementitious material,polymer, inorganic material, fatty acid, fatty acids salt, and mixturesthereof; the second layer being adjacent to the bottom surface of thefirst layer so as to cover the bottom surface of the first layer; thesecond layer also being substantially cylindrical and having a diametersubstantially equal to that of the first layer so that an exteriorperipheral surface of both the first layer and adjacent second layer aresubstantially flush with one another; and wherein the first layer andthe second layer are not effervescent.

Further features and advantages of the present invention will becomeapparent to those of ordinary skill in the art in view of the detaileddescription of preferred embodiments below.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of thepresent invention, a more particular description of the invention willbe rendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It is appreciated that thesedrawings depict only typical embodiments of the invention and aretherefore not to be considered limiting of its scope. The invention willbe described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 depicts a perspective view of an exemplary shaped composition;

FIG. 2 is a cross-sectional view through the composition of FIG. 1;

FIG. 2A is a cross-sectional view through an alternative compositionsimilar to that shown in FIG. 2, but including an indicating feature forindicating to the user that the shaped composition should be replaced;

FIG. 2B is a cross-sectional view through another shaped compositionincluding an alternative indicating feature;

FIG. 3 is a perspective view of an exemplary shaped compositioncomprising a hollow cylinder;

FIG. 4 is a perspective view of an exemplary shaped compositionincluding a third region;

FIG. 5 is a table showing compositional characteristics of examplecompositions that were made;

FIG. 6 plots the effects of various adjuvants on dissolution rate ofhypochlorite in the dissolving region or layer;

FIG. 7 plots interactions for various the various adjuvants shown inFIG. 6;

FIG. 8 includes contour plots of dissolution rate per area for thevarious adjuvants of FIG. 6;

FIG. 9 is a graph showing the dissolution characteristics of compositionexample 30 a;

FIG. 10 is a graph showing the dissolution characteristics ofcomposition example 30 b;

FIG. 11 is a graph showing the dissolution characteristics ofcomposition example 31 a;

FIG. 12 is a graph showing the dissolution characteristics ofcomposition example 31 b;

FIG. 13 is a diagram of an exemplary cylinder;

FIG. 14 is a perspective view of a hollow cylinder shaped compositionincluding no non-dissolvable region;

FIG. 15 is a perspective view of a hollow cylinder shaped compositionincluding a non-dissolvable region blocking the bottom of the hollowcylinder;

FIG. 16 is a perspective view of a hollow cylinder shaped compositionincluding a dissolvable region sandwiched between two non-dissolvableregions; and

FIG. 17 is a perspective view of a hollow cylinder shaped compositionincluding a non-dissolvable region that covers a top surface of thedissolvable region.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Introduction

Before describing the present invention in detail, it is to beunderstood that this invention is not limited to particularlyexemplified systems or process parameters that may, of course, vary. Itis also to be understood that the terminology used herein is for thepurpose of describing particular embodiments of the invention only, andis not intended to limit the scope of the invention in any manner.

All publications, patents and patent applications cited herein, whethersupra or infra, are hereby incorporated by reference in their entiretyto the same extent as if each individual publication, patent or patentapplication was specifically and individually indicated to beincorporated by reference.

The term “comprising” which is synonymous with “including,”“containing,” or “characterized by,” is inclusive or open-ended and doesnot exclude additional, unrecited elements or method steps.

The term “consisting essentially of” limits the scope of a claim to thespecified materials or steps “and those that do not materially affectthe basic and novel characteristic(s)” of the claimed invention.

The term “consisting of” as used herein, excludes any element, step, oringredient not specified in the claim.

It must be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an” and “the” include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a “surfactant” includes one, two or more such surfactants.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention pertains. Although a number of methodsand materials similar or equivalent to those described herein can beused in the practice of the present invention, the preferred materialsand methods are described herein.

In the application, effective amounts are generally those amounts listedas the ranges or levels of ingredients in the descriptions, which followhereto. Unless otherwise stated, amounts listed in percentage (“wt %'s”)are in wt % (based on 100 weight % active) of the particular materialpresent in the referenced composition, any remaining percentage beingwater or an aqueous carrier sufficient to account for 100% of thecomposition, unless otherwise noted.

General

The present invention is directed to shaped compositions for use indelivering a substantially uniform concentration of a functional agent(e.g., an antimicrobial sanitizing agent) to a flowing stream of water.In one embodiment, the composition is shaped and sized to be insertedinto a device configured to be attached over the end of a faucet (e.g.,a sink or shower faucet). In one embodiment, the shaped compositionincludes at least two different regions which may be configured aslayers. In another embodiment, the shaped composition includes a thirdregion. A dissolvable region includes a functional agent, for example,an anti-microbial sanitizing agent that can be used to provide afood-safe anti-microbial sanitizing wash for foods (e.g., lettuce,strawberries, etc.), hands, hard surfaces, soft surfaces, etc.Additionally, an anti-microbial sanitizing agent can allow for rinsingof sponges, cutting boards, utensils, child cups or anything else a usermay be concerned has hidden germs.

The dissolvable region is shaped so as to include a top surface, abottom surface, and a peripheral surface. A substantiallynon-dissolvable region is disposed adjacent to the dissolvable region(e.g., adjacent the bottom surface) so as to cover the bottom surface ofthe dissolvable region, minimizing or preventing water contact with thissurface. The substantially non-dissolvable region remains substantiallyintact as the dissolving region is progressively dissolved during use.The presence of the substantially non-dissolvable region aids inproviding a substantially uniform concentration of functional agentthroughout the life of the dissolvable region.

During use, a flow of water is contacted with a surface of thedissolvable region so that the functional agent within the dissolvableregion is dissolved into the water, which then exits the device attachedover the dispensing end of the faucet. The device including the shapedcomposition may be used to deliver a flow of anti-microbial sanitizingwater, or a flow of water including other functional agents includedtherein.

In one embodiment, the flow of water may be intermittently appliedduring use. The shaped composition may include features to minimizecontinued dissolution of the composition when the flow of water hasstopped. For example, the shaped composition may be configured tofacilitate drainage of water away from the composition so as to providemore uniform dispensing of functional agent even under intermittent useconditions. In one embodiment the composition is shaped so that gravitypulls the water away from the composition. For example, the top of thetablet or other shaped composition may have a high point near its centerso that water flows to the edges. The bottom of the shaped compositionmay have a low point near its center towards which the water will flowand accumulate to form drops that fall away from the composition.

In one embodiment, one or more protrusions (e.g. pins) may protrude fromthe bottom of the shaped composition. Water will thus tend to flow tothe tips of such protrusions, away from the surface of the composition.The protrusions may comprise a material that is more hydrophilic thanthe surface of the tablet. Preferably, the protrusions may besubstantially non-dissolvable. In one embodiment, such protrusions maycomprise the same material as the substantially non-dissolving layer.Such protrusions may be part of (e.g., comprise a single integral piecewith) or otherwise be attached to the substantially non-dissolvinglayer, or they may be a separate component of the composition. Tofurther facilitate drainage of water, the surface of the composition,any protrusions, or both may have grooves formed therein.

Exemplary functional agents may provide a soap for washing dishes,hands, hard surfaces, soft surfaces, other surfaces, a disinfectingkitchen or bathroom cleaner, a disinfecting shower cleaner, ananti-microbial sanitizing rinse for a bathroom faucet (e.g.,sufficiently gentle to be used on toothbrushes, retainers, hands, etc.),flavored water beverage that may include antioxidants. Functional agentscan also or alternatively include vitamins for conferring a healthbenefit to the consumer, minerals for conferring a health benefit to theconsumer, remove chemicals and pesticides from food, dilution for othercleaners, a light kitchen cleaner, a dish soap sufficiently mild forhands, a facial wash, softened tap water. In addition, functional agentscan include a strong shower cleaner, tap water free of chlorine andodor, a concentrated disinfecting cleaner, a drain cleaner, amoisturizing body wash from a shower faucet, an aromatherapy wash from ashower faucet, or a gentle skin sanitizer from a shower faucet.Additional exemplary functional agents will be apparent to one of skillin the art in light of the present disclosure.

While this invention discloses various compositions, the invention alsoencompasses a system (i.e. device with composition) for conditioning andmethod patent claims (i.e. method of sanitizing, method of sanitizingusing a faucet mount that rotates or flips from an active position to aninactive position (and vice versa) without dismounting from the faucet,method of rinsing an object and putting it aside, etc.).

As used herein, the term “dissolve” is to be broadly construed toinclude dissolution, as well as entrainment or other introduction of afunctional agent into a flowing stream of water. For example, while somefunctional agents may be lipophilic (e.g., fragrances) so as to nottruly dissolve within the stream of water, they can be entrained orotherwise introduced into the stream of water, and for the sake ofsimplicity, such materials may be broadly be described as dissolvinginto the flowing stream of water as that term is used herein.

Exemplary Shaped Compositions for Substantially Uniform Delivery of aFunctional Agent

FIGS. 1 and 2 illustrate perspective and cross-sectional views,respectively of an exemplary shaped composition 100 including adissolvable region 102 and an adjacent substantially non-dissolvableregion 104. In a preferred embodiment, the shaped composition 100 may besubstantially cylindrical. In one embodiment, the dissolvable portion102 of the substantially cylindrical composition 100 may have a diametergreater than the height so as to provide a relatively short, squat,puck-like configuration. In one embodiment, the ratio of the diameter toheight is at least about 1, at least about 1.5, at least about 2, atleast about 3, or at least about 5. In another embodiment, the ratio ofthe diameter to the height is at least about 0.1, at least about 0.2, atleast about 0.3, at least about 0.4, at least about 0.5, at least about0.6, at least about 0.7, at least about 0.8, at least about 0.9, or atleast about 1.

Region 102 includes a top surface 106, a bottom surface 108, and aperipheral surface 110. Non-dissolvable region 104 may include a similarcross-sectional shape as dissolvable region 102 (e.g., it may also becylindrical). As shown, non-dissolvable region 104 is disposed adjacentto bottom surface 108 of dissolvable region 102. In one embodiment,substantially the entire bottom surface 108 is covered bynon-dissolvable region 104. Such configurations aid in providing asubstantially uniform concentration of functional agent throughout thelife of the dissolvable region 102, as will be explained in furtherdetail hereafter. Non-dissolvable region 104 and dissolvable region 102may both be substantially cylindrical and have a diameter substantiallyequal to one another so that an exterior peripheral surface of both thefirst layer and adjacent second layer are substantially flush with oneanother, as shown in FIGS. 1-2.

Relatively high aspect ratios of diameter to height of region 102, aswell as covering bottom surface 108 of region 102, aids in providing asubstantially uniform concentration of functional agent throughout thelife of region 102. For example, the rate of dissolution of region 102is dependent on the surface area along which dissolution is occurring atany given time. Maintaining a substantially uniform rate of dissolutionaids in maintaining a substantially uniform concentration of functionalagent within the water stream. Because of this dependency, shapes andorientations configured to provide substantially equal surface areaalong which dissolution occurs during the life of the shaped compositionare preferred. For example, a cylindrical configuration in whichdissolution occurs as a result of height reduction is one preferredconfiguration, as the surface area of the top surface, where dissolutionprincipally occurs when the water stream is delivered to this surface,remains the same as the height of the cylinder is progressively reduced.

Other shapes providing this same characteristic could alternatively beused (e.g., a rectangular prism, a modified cylinder having an ovaltransverse cross-section, etc.). Such shapes providing a substantiallyconstant cross-sectional surface area as the shape is reduced throughreduction in the height are preferred because the surface area alongwhich dissolution of the functional agent occurs remains substantiallyconstant throughout the course of use. For example, with a cylindricalshaped composition, because the dissolution of the dissolvable regionoccurs through the mechanism of height reduction, and because a cylinderhas a circular cross-section whose cross-sectional area remains the samethrough any given location of the cylinder, the rate of dissolution ofthe dissolvable region (and thus the functional agent) remainssubstantially constant throughout the life of the shaped composition.

The relative constancy of the dissolution rate (and thus concentrationof the functional agent within the delivered stream of water) is furtheraided by providing a substantially non-dissolvable region 104 disposedadjacent to the dissolvable region 102. For example, by positioning thenon-dissolvable region 104 against the bottom surface 108 of region 102,water is not easily able to contact bottom surface 108 so as to dissolvethis region until the material disposed above bottom surface 108 isfirst dissolved. This is beneficial as although theoreticallydissolution occurs via height reduction, often the top surface may notremain horizontal or flat, as some portions may tend to dissolve fasterthan others, which can often result in faster erosion adjacent theperipheral edge.

By covering bottom surface 108 so that it does not participate in thedissolution, this effect is limited to only the top surface, effectivelycutting this non-uniformity in half as compared to if both top andbottom surfaces were exposed. This prevents changes in the surface areaof dissolvable region 102 which may otherwise occur if water wereallowed to contact bottom surface 108, so that the surface area alongwhich dissolution is occurring at any given time remains substantiallyconstant.

A relatively high aspect ratio of the diameter (in the case of acylinder) or width of the shaped dissolvable region relative to theheight of the dissolvable region is also helpful in maintaining arelatively constant dissolution rate. For example, where the diameter,or width of region 102 is greater than the height of region 102, thismaximizes the fraction of the exterior surface area of the cylinder orother shaped composition that is located along the top surface, whilethat surface area which is located along the peripheral surface isminimized.

This is helpful because, as the dissolvable region 102 is progressivelydissolved, the top surface 106 provides the same surface area, but thesurface area provided by peripheral surface 110 changes as the height ofregion 102 decreases. This is important as some water may contactperipheral region 110 so that dissolution occurs at this surface as wellas top surface 106. This introduces a variable surface area along whichdissolution is occurring as the dissolvable region progressively shrinksdue to dissolution. This can be undesirable to the extent it results inchanges to the concentration of functional agent provided within thedelivered stream of water.

It can thus be preferable to limit the surface area associated withperipheral surface 110, to limit contact of the water stream withsurface 110, and perhaps even to provide a non-dissolvable portion tocover peripheral surface 110 so as to minimize or prevent dissolutionfrom occurring at this surface. As discussed above, it is preferable fordissolution to occur only along top surface 106 so as to provide asubstantially uniform concentration of a functional agent to the flowingstream of water (e.g., that may be directed to contact top surface 106).

As explained, in one embodiment, the aspect ratio of the width of region102 to height of region 102 is at least about 1, at least about 1.5, atleast about 2, at least about 3, or at least about 5. For example,according to one embodiment, the region 102 may have a diameter of about3 cm and a height of about 0.6 cm, providing an aspect ratio of about 5.Relatively higher aspect ratios minimize any negative effect thatperipheral surface 110 may have on the total surface area along whichdissolution is occurring at any given time. In one aspect, this isbecause the great majority of the exterior surface area is located alongthe top surface rather than the peripheral surface.

In one embodiment, the shaped composition, including both dissolvableregion 102 and non-dissolvable region 104 may comprise a hollowcylinder. In some embodiments, it may even be possible to provide ashaped composition without the non-dissolvable backing layer where theaspect ratio is particularly high (e.g., about 2 or more, 3 or more, or4 or more). Of course, including a non-dissolvable layer or region insuch embodiments may provide even more uniform delivery of thefunctional agent.

In one embodiment, the shaped composition, including the non-dissolvableregion 104 may comprise an indicating feature. Such an indicatingfeature may include a contrastingly colored portion of region 104 thatis adjacent to surface 108. For example, where the non-dissolvableregion and dissolvable regions are lightly colored, at least a portionof a top surface of region 104 may be colored (e.g., red, blue, purple,black, green, etc.) to contrast with the color(s) of regions 102 and104, so as to be apparent to the user when the dissolvable region 102 issubstantially exhausted. This indicates that the entire shapedcomposition 100 should be replaced, as the functional ingredient ofregion 102 has been substantially exhausted.

In one embodiment, the contrastingly colored surface of region 104 maynot necessarily be horizontal or flat as shown in FIG. 2, but mayinclude a portion that protrudes towards dissolvable region 102. Asdissolvable region 102 is progressively dissolved away through heightreduction, the protruding portion of region 104 will become visiblebefore adjacent “lower” portions of region 104 because the heightdimension of the dissolvable region 102 at these locations is thinnerthan adjacent locations.

For example FIG. 2A shows an embodiment in which the portions adjacentperipheral edge 111 of non-dissolvable region 104 are thicker than acentral portion of region 104. As such, as dissolvable region 102 isprogressively dissolved through height reduction, the thicker peripheralportion adjacent edge 111 will show through dissolvable region 102 oncesufficient dissolution of region 102 has occurred. FIG. 2B shows analternative embodiment in which the central portion of region 104 isthicker than peripheral portion adjacent edge 111. As such, asdissolvable region 102 is progressively dissolved, the thicker centralportion of region 104 will show through dissolvable region 102,indicating a need to replace the shaped composition.

In other words, in each case, the thickness of dissolvable portion 102is not constant, but includes a thinner portion which will be dissolvedthrough fastest, and the underlying contrastingly colorednon-dissolvable surface top surface of region 104 adjacent bottomsurface 108 will show through, indicating to the user that the shapedcomposition should be replaced. The faucet mountable device retainingthe shaped composition may be transparent or include a transparentwindow portion to allow the user to more easily visually observe such anindicator feature. Alternative indicating features will be apparent toone of skill in the art in light of the present disclosure.

In one embodiment, the indicating feature may include a mechanicalmechanism to prevent the device within which the shaped composition ishoused from operating further until the exhausted shaped composition hasbeen replaced.

One or more functional agents are included in the dissolvable region ofthe shaped composition to provide a functional benefit that may include,but not limited to, antimicrobial sanitation, pleasant fragrance,improve soil removal, increase wetting, inhibit corrosion, or provideother, desirable benefits. Exemplary functional agents include, but arenot limited to, an antimicrobial sanitizing agent, a pH adjusting agent,a surfactant, a hydrotrope, a wetting agent, a mineral, a vitamin, apenetrant, a chelating agent, an odor masking agent, an odor absorbingagent, a colorant, a fluorescent whitening agent, a flavoring agent, afragrance, a sweetener, a potentiator, a sporulation agent, a corrosioninhibitor, a therapeutic agent, a viscosity modifier, a foam stabilizer,a foam booster, a defoamer, a stain and soil repellent, an enzyme, acloud point modifier, a dispersant, a catalyst, an activating agent, awater softening agent, and combinations thereof.

More than one functional agent may be included to provide multiplebenefits. In some cases, combinations of different types of functionalagents may be provided. For example, one shaped composition may includean odor absorbing agent and an odor masking agent or fragrance toprovide better odor control than when only one of these agents arepresent. In another example, combining surfactants with hydrotropes orwetting agents may synergistically enhance cleaning or antimicrobialproperties.

The functional agents may be present in the dissolvable region at alevel of from about 0.1% to about 100%, from about 0.1% to about 80%,from about 0.1% to about 60%, from about 0.1% to about 40%, from about0.1% to about 20%, from about 0.1% to about 15%, from about 0.1% toabout 10%, from about 0.1% to about 5%, from about 0.1% to about 1%,from about 0.01% to about 1%, from about 5% to about 50%, from about 5%to about 25%, from about 5% to about 15%, from about 5% to about 10%,from about 10% to about 60%, from about 10% to about 40%, from about 10%to about 20%, from about 20% to about 60%, about 20% to about 40%, about15% to about 25%, about 50% to about 100%, about 60% to about 100%,about 70% to about 100%, about 80% to about 100%, or about 90% to about100%.

The dissolvable region can comprise a functional agent that becomesentrained, dissolved, or otherwise introduced into the flowing stream ofwater. In one embodiment, the functional agent comprises anantimicrobial sanitizing agent. Examples of such sanitizing agentsinclude, but are not limited to, hypochlorites, peroxides, quaternaryammonium compounds, silver salts, N-halogen compounds, or antimicrobialorganic acids such as citric acid, lactic acid, lauric acid, and/orglycolic acid. In one embodiment, the dissolvable region comprises asolid. In another embodiment, it may comprise a gel. Liquidantimicrobial sanitizing agents (e.g., an organic acid or an aqueous orother liquid carrier solution of a peroxide or hypochlorite) may beincorporated within such a gel.

Exemplary hypochlorites include, but are not limited to, hypochloritesalts of alkaline or alkaline earth metals. Particularly preferredmaterials include calcium hypochlorite, magnesium hypochlorite, andmixtures thereof. In one embodiment, the functional agent contains nosodium hypochlorite. In another embodiment, the functional agentcontains no lithium hypochlorite. In another embodiment, neither thefirst region or first layer nor the second region or layer containssodium hypochlorite or lithium hypochlorite. Exemplary peroxidesinclude, but are not limited to, aqueous hydrogen peroxide, solidcomplexes of hydrogen peroxide, and mixtures thereof. Non-limitingexamples of solid complexes of hydrogen peroxide include, but are notlimited to, carbamide peroxide and metal perborates (e.g., sodiumperborate), metal percarbonates (e.g., sodium percarbonate), metalperoxides, metal chlorites, metal peroxy acids, metal peroxy acid salts,and mixtures thereof. The metals may typically be alkaline or alkalineearth metals. In one embodiment, a peroxide may be formed in-situ byproviding a sugar (e.g., glucose) into the stream of water, which streamof water then contacts another layer or region including a sugar oxidase(e.g., glucose oxidase), which forms the desired sanitizing peroxide.

Exemplary quaternary ammonium compounds include, but are not limited to,quaternary ammonium organohalides such as benzalkonium chloride, alkylbenzyl dimethyl ammonium halide, alkyl dimethyl ethyl benzyl ammoniumhalide, n-alkyl dimethyl benzyl ammonium halide, diisobutyl phenoxyethoxy ethyl dimethyl benzyl ammonium halide, n-(C₁₂C₁₄C₁₆) alkyldimethyl benzyl ammonium halide, dodecyl dimethyl ammonium halide,dioctyl dimethyl ammonium halide, dialkyl dimethyl ammonium halide,dialkyl methyl benzyl ammonium halide, octyl decyl dimethyl ammoniumhalide, lauryl dimethyl benzyl ammonium halide, o-benzyl-p-chlorophenol,dideryl dimethyl ammonium halide, dioctyl dimethyl ammonium halide,alkyl (C₁₄C₁₂C₁₆) dimethyl benzyl ammonium halide, and mixtures thereof.In one embodiment, the quaternary ammonium compound may include an alkylgroup having between about 6 to about 18 carbon atoms.

Exemplary N-halogen compounds include trichloro-s-triazinetrione,trichloromelamine, 1,3-dichloro-5 ethyl-5 methylhydantoin,1,3-dichloro-5-5-dimethylhydantoin, sodium dichloroisocyanurate, andmixtures thereof. Preferably, any included N-halogen compounds do notproduce gaseous diatomic halogens (e.g., F₂, Cl₂, Br₂, I₂, etc.) duringuse (e.g., upon exposure to water).

In another embodiment, the functional agent comprises a surfactant. Theterm “surfactant”, as used herein, refers to and includes a substance orcompound that reduces surface tension when dissolved in water or aqueoussolutions, or that reduces interfacial tension between two liquids, orbetween a liquid and a solid. The term “surfactant” thus includesanionic, nonionic, cationic, zwiterrionic and/or amphoteric agents.

The dissolvable region may contain one or more surfactants selected fromnonionic, anionic, cationic, ampholytic, amphoteric and zwitterionicsurfactants and mixtures thereof. Preferably, any surfactant is presentin the dissolvable region of the composition. A typical listing ofanionic, ampholytic, and zwitterionic classes, and species of thesesurfactants, is given in U.S. Pat. No. 3,929,678 to Laughlin andHeuring. A list of suitable cationic surfactants is given in U.S. Pat.No. 4,259,217 to Murphy, each of which is herein incorporated byreference.

The dissolvable region may comprise an anionic surfactant. Essentiallyany anionic surfactants useful for detersive purposes can be used in thecleaning composition. These can include salts (including, for example,sodium, potassium, ammonium, and substituted ammonium salts such asmono-, di- and tri-ethanolamine salts) of the anionic sulfate,sulfonate, carboxylate and sarcosinate surfactants. Anionic surfactantsmay comprise a sulfonate or a sulfate surfactant. Anionic surfactantsmay comprise an alkyl sulfate, a linear or branched alkyl benzenesulfonate, or an alkyldiphenyloxide disulfonate, as described herein.

Other anionic surfactants include the isethionates such as the acylisethionates, N-acyl taurates, fatty acid amides of methyl tauride,alkyl succinates and sulfosuccinates, monoesters of sulfosuccinate (forinstance, saturated and unsaturated C₁₂-C₁₈ monoesters) diesters ofsulfosuccinate (for instance saturated and unsaturated C₆-C₁₄ diesters),N-acyl sarcosinates. Resin acids and hydrogenated resin acids are alsosuitable, such as rosin, hydrogenated rosin, and resin acids andhydrogenated resin acids present in or derived from tallow oil. Anionicsulfate surfactants suitable for use herein include the linear andbranched primary and secondary alkyl sulfates, alkyl ethoxysulfates,fatty oleoyl glycerol sulfates, alkyl phenol ethylene oxide ethersulfates, the C₅-C₁₇ acyl-N—(C₁-C₄ alkyl) and —N—(C₁-C₂ hydroxyalkyl)glucamine sulfates, and sulfates of alkylpolysacchanides such as thesulfates of alkylpolyglucoside (the nonionic nonsulfated compounds beingdescribed herein). Alkyl sulfate surfactants may be selected from thelinear and branched primary C₁₀-C₁₈ alkyl sulfates, the C₁₁-C₁₅ branchedchain alkyl sulfates, or the C₁₂-C₁₄ linear chain alkyl sulfates.

Alkyl ethoxysulfate surfactants may be selected from the groupconsisting of the C₁₀-C₁₈ alkyl sulfates, which have been ethoxylatedwith from about 0.5 to about 20 moles of ethylene oxide per molecule.The alkyl ethoxysulfate surfactant may be a C₁₁-C₁₈, or a C₁₁-C₁₅ alkylsulfate which has been ethoxylated with from about 0.5 to about 7, orfrom about 1 to about 5, moles of ethylene oxide per molecule. Oneembodiment may include mixtures of the alkyl sulfate and/or sulfonateand alkyl ethoxysulfate surfactants. Such mixtures have been disclosedin PCT Patent Application No. WO 93/18124, herein incorporated byreference.

Anionic sulfonate surfactants suitable for use herein include the saltsof C₅-C₂₀ linear alkylbenzene sulfonates, alkyl ester sulfonates, C₆-C₂₂primary or secondary alkane sulfonates, C₆-C₂₄ olefin sulfonates,sulfonated polycarboxylic acids, alkyl glycerol sulfonates, fatty acylglycerol sulfonates, fatty oleyl glycerol sulfonates, and any mixturesthereof. Suitable anionic carboxylate surfactants include alkyl ethoxycarboxylates, alkyl polyethoxy polycarboxylate surfactants and soaps(“alkyl carboxyls”), especially certain secondary soaps as describedherein. Suitable alkyl ethoxy carboxylates include those with theformula

RO(CH2CH2O)xCH2COO—M+

wherein R is a C₆ to C₁₈ alkyl group, x ranges from 0 to 10, and theethoxylate distribution is such that, on a weighi basis, the amount ofmaterial where x is 0 is less than 20% and M is a cation. Suitable alkylpolyethoxypolycarboxylate surfactants include those having the formulaRO—(CHR₁—CHR₂—O)—R₃ wherein R is a C₆ to C₁₈ alkyl group, x is from 1 to25, R₁ and R₂ are selected from the group consisting of hydrogen, methylacid radical, succinic acid radical, hydroxysuccinic acid radical, andmixtures thereof, and R₃ is selected from the group consisting ofhydrogen, substituted or unsubstituted hydrocarbons having between 1 and8 carbon atoms, and mixtures thereof

Suitable soap surfactants include the secondary soap surfactants, whichcontain a carboxyl unit connected to either a primary or secondarycarbon. Suitable secondary soap surfactants for use herein arewater-soluble members selected from the group consisting ofwater-soluble salts of 2-methyl-1-undecanoic acid, 2-ethyl-1-decanoicacid, 2-propyl-1-nonanoic acid, 2-butyl-1-octanoic acid and2-pentyl-1-heptanoic acid. Certain soaps may also be included as sudssuppressors.

Other suitable anionic surfactants are the alkali metal sarcosinates offormula R—CON(R₁) CH—)COOM, wherein R is a C₅-C₁₇ linear or branchedalkyl or alkenyl group, R₁ is a C₁-C₄ alkyl group and M is an alkalimetal ion. Examples are the myristyl and oleoyl methyl sarcosinates inthe form of their sodium salts.

Other suitable surfactants include fatty acid sarosinates which aremild, biodegradable anionic surfactants derived from fatty acids andsarcosine (amino acid). Sarcosine is the N-methyl derivative of glycine.Sarcosine is a natural amino acid found in muscles and other tissues.Sarcosine is found naturally as an intermediate in the metabolism ofcholine to glycine. In a preferred embodiment, the sarcosines are acylsarcosines. Examples of acyl sarcosines include, but are not limited to,cocoyl sarcosine, lauroyl sarcosine, myristoyl sarcosine, oleoylsarcosine, and stearoyl sarcosine which are modified fatty acids. Thesalts of acyl sarcosines are referred to as acyl sarcosinates. Acylsarcosinates useful herein include, for example, those having a formula:

RCON(CH₃)CH₂COOX

wherein R is an alkyl or alkenyl having from about 8 to about 22 carbonatoms, preferably from about 12 to about 18 carbon atoms, morepreferably from about 12 to about 14 carbon atoms, and X is a sodium,potassium, ammonium, or triethanolamine.

Examples of acyl sarcosinates that can be used with the presentinvention include, but are not limited to, sodium coccyl sarcosinate,sodium lauroyl sarcosinate and sodium myristoyl sarcosinate, sodiumoleoyl sarcosinate, sodium stearoyl sarcosinate, ammonium coccylsarcosinate, ammonium lauroyl sarcosinate and ammonium myristoylsarcosinate, ammounium oleoyl sarcosinate and ammonium stearoylsarcosinate. Commercially available preferred acyl sarcosinates include,but are not limited to, sodium lauroyl sarcosinate having the tradenameHAPMOSYL L30 which is available from Hampshire Chemicals, and sodiumcocoyl sarcosinate having the tradename HAMPOSYL C30, also availablefrom Hampshire Chemicals.

Other suitable surfactants include fatty alcohol sulfates which have ahigher alcohol or alkyl group normally in the range of about 10 to about18 carbon atoms. The cation will almost invariably be sodium or willinclude sodium, although other cations, such as triethanolamine,potassium, ammonium, magnesium and calcium may also be used. Preferredfatty alcohol sulfates are those wherein the fatty alcohol isessentially saturated and is of a carbon content within the 10 to 18carbon atoms range, preferably 10 or 12 to 14 or 16 carbon atoms, suchas 12 to 16, or that is derived from coconut oil (coco), palm oil, orpalm kernel oil.

Lauryl sulfates, and particularly, sodium lauryl sulfate, are preferredprimary detergents but such designation also may apply to suchdetergents wherein the carbon chain length of the alcohol is not limitedto about 12 carbon atoms, but is primarily (over 50% and normally over70% or 75%) of 12 to 14 carbon atoms. Such materials may be obtainedfrom natural sources, such as coconut oil and palm kernel oil. In oneembodiment, the fatty alcohol sulfate is a C₁₂-C₁₈ fatty alcoholsulfate. In another embodiment, the fatty alcohol sulfate is a C₁₂-C₁₆fatty alcohol sulfate. In another embodiment, the fatty alcohol sulfateis a C₁₂-C₁₄ fatty alcohol sulfate. In another embodiment, the fattyalcohol is a C₁₂ fatty alcohol sulfate. In another embodiment, the fattyalcohol sulfate is sodium lauryl sulfate. In a specific embodiment, thefatty alcohol sulfate is a sodium coco fatty alcohol sulfate.

Suitable amphoteric surfactants for use herein include amine oxidesurfactants and alkyl amphocarboxylic acids. Suitable amine oxidesinclude those compounds having the formula R₃ (OR₄)XNO(R₅)₂ wherein R₃is selected from an alkyl, hydroxyalkyl, acylamidopropyl and alkylphenylgroup, or mixtures thereof, containing from about 8 to about 26 carbonatoms; R₄ is an alkylene or hydroxyalkylene group containing from 2 to 3carbon atoms, or mixtures thereof, x is from 0 to 5, preferably from 0to 3; and each R₅ is an alkyl or hydroxyalkyl group containing from 1 to3, or a polyethylene oxide group containing from 1 to 3 ethylene oxidegroups. Suitable amine oxides are C₁₀-C₁₈ alkyl dimethylamine oxide, andC₁₀-C₁₈ acylamido alkyl dimethylamine oxide. A suitable example of analkyl amphodicarboxylic acid is MIRANOL C2M Conc. manufactured byMiranol, Inc., Dayton, N.J.

Zwitterionic surfactants can also be incorporated into the shapedcompositions. These surfactants can be broadly described as derivativesof secondary and tertiary amines, derivatives of heterocyclic secondaryand tertiary amines, or derivatives of quaternary ammonium, quaternaryphosphonium or tertiary sulfonium compounds. Betaine and sultainesurfactants are exemplary zwittenionic surfactants for use herein.

Suitable betaines are those compounds having the formula R(R₁)₂N+R₂COO—wherein R is a C₆-C₈ hydrocarbyl group, each R₁ is typically a C₁-C₃alkyl, and R₂ is a C₁-C₅ hydrocarbyl group. Suitable betaines are C₁₂₋₁₈dimethyl-ammonio hexanoate and the C₁₀-C₁₈ acylamidopropane (or ethane)dimethyl (or diethyl) betaines. Complex betaine surfactants are alsosuitable for use herein.

Suitable cationic surfactants to be used herein include the quaternaryammonium surfactants. The quaternary ammonium surfactant may be a monoC₆-C₁₆, or a C₆-C₁₀N-alkyl or alkenyl ammonium surfactant wherein theremaining N positions are substituted by methyl, hydroxyethyl orhydroxypropyl groups. Suitable are also the mono-alkoxylated andbis-alkoxylated amine surfactants. Additional suitable cationicsurfactants include coco fatty acid diethanolamine, hydrogenated palmtea ester quat, and cationic ethyoxylate fatty acids.

Another suitable group of cationic surfactants, which can be used in theshaped compositions, are cationic ester surfactants. The cationic estersurfactant is a compound having surfactant properties comprising atleast one ester (i.e. —COO—) linkage and at least one cationicallycharged group. Suitable cationic ester surfactants, including cholineester surfactants, have for example been disclosed in U.S. Pat. Nos.4,228,042, 4,239,660 and 4,260,529, each of which is herein incorporatedby reference.

The ester linkage and cationically charged group may be separated fromeach other in the surfactant molecule by a spacer group of a chaincomprising at least three atoms (i.e. of three atoms chain length), orfrom three to eight atoms, or from three to five atoms, or three atoms.The atoms forming the spacer group chain are selected from the groupconsisting of carbon, nitrogen, oxygen, and any mixtures thereof, withthe proviso that any nitrogen or oxygen atoms in said chain connect onlywith carbon atoms in the chain. Thus spacer groups having, for example,—O—O— (i.e. peroxide), —N—N—, and —N—O— linkages are excluded, whilstspacer groups having, for example —CH₂—O—, CH₂— and —CH₂—NH—CH₂—linkages are included. The spacer group chain may comprise only carbonatoms, or the chain is a hydrocarbyl chain.

The dissolvable region may comprise cationic mono-alkoxylated aminesurfactants, for instance, of the general formula: R₁R₂R₃N+A_(p)R₄X—wherein R₁ is an alkyl or alkenyl moiety containing from about 6 toabout 18 carbon atoms, or from 6 to about 16 carbon atoms, or from about6 to about 14 carbon atoms; R₂ and R₃ are each independently alkylgroups containing from one to about three carbon atoms, for instance,methyl, for instance, both R₂ and R₃ are methyl groups; R₄ is selectedfrom hydrogen, methyl and ethyl; X— is an anion such as chloride,bromide, methylsulfate, sulfate, or the like, to provide electricalneutrality; A is a alkoxy group, especially a ethoxy, propoxy or butoxygroup; and p is from 0 to about 30, or from 2 to about 15, or from 2 toabout 8.

The A_(p)R₄ group in the formula may have p=1 and is a hydroxyalkylgroup, having no greater than 6 carbon atoms whereby the —OH group isseparated from the quaternary ammonium nitrogen atom by no more than 3carbon atoms. Suitable ApR₄ groups are —CH₂CH₂—OH, —CH₂CH₂CH₂—OH,—CH₂CH(CH₃)—OH and —CH(CH₃)CH₂—OH. Suitable R₁ groups are linear alkylgroups, for instance, linear R₁ groups having from 8 to 14 carbon atoms.

Suitable cationic mono-alkoxylated amine surfactants for use herein areof the formula R₁(CH₃)(CH₃)N+(CH₂CH₂O)₂-5H X— wherein R₁ is C₁₀-C₁₈hydrocarbyl and mixtures thereof, especially C₁₀-C₁₄ alkyl, or C₁₀ andC₁₂ alkyl, and X is any convenient anion to provide charge balance, forinstance, chloride or bromide.

As noted, compounds of the foregoing type include those wherein theethoxy (CH₂CH₂O) units (EO) are replaced by butoxy, isopropoxy[CH(CH₃)CH₂O] and [CH₂CH(CH₃)O]units (i-Pr) or n-propoxy units (Pr), ormixtures of EO and/or Pr and/or i-Pr units.

The cationic bis-alkoxylated amine surfactant may have the generalformula: R₁R₂N+A_(p)R₃A′_(q)R₄X— wherein R₁ is an alkyl or alkenylmoiety containing from about 8 to about 18 carbon atoms, or from 10 toabout 16 carbon atoms, or from about 10 to about 14 carbon atoms; R₂ isan alkyl group containing from one to three carbon atoms, for instance,methyl; R₃ and R₄ can vary independently and are selected from hydrogen,methyl and ethyl, X— is an anion such as chloride, bromide,methylsulfate, sulfate, or the like, sufficient to provide electricalneutrality. A and A′ can vary independently and are each selected fromC₁-C₄ alkoxy, for instance, ethoxy, (i.e., —CH₂CH₂O—), propoxy, butoxyand mixtures thereof, p is from 1 to about 30, or from 1 to about 4 andq is from 1 to about 30, or from 1 to about 4, or both p and q are 1.

Suitable cationic bis-alkoxylated amine surfactants for use herein areof the formula R₁CH₃N+(CH₂CH₂OH)(CH₂CH₂OH) X—, wherein R₁ is C₁₀-C₁₈hydrocarbyl and mixtures thereof, or Co, C₁₂, C₁₄ alkyl and mixturesthereof, X— is any convenient anion to provide charge balance, forexample, chloride. With reference to the general cationicbis-alkoxylated amine structure noted above, since in one examplecompound R₁ is derived from (coconut) C₁₂-C₁₄ alkyl fraction fattyacids, R₂ is methyl and A_(p)R₃ and A′_(q)R₄ are each monoethoxy.

Other cationic bis-alkoxylated amine surfactants useful herein includecompounds of the formula: R₁R₂N+-(CH₂CH₂O)_(p)H—(CH₂CH₂O)_(q)H X—wherein R₁ is C₁₀-C₁₈ hydrocarbyl, or C₁₀-C₁₄ alkyl, independently p is1 to about 3 and q is 1 to about 3, R₂ is C₁-C₃ alkyl, for example,methyl, and X— is an anion, for example, chloride or bromide.

Other compounds of the foregoing type include those wherein the ethoxy(CH₂CH₂O) units (EO) are replaced by butoxy (Bu) isopropoxy[CH(CH₃)CH₂O] and [CH₂CH(CH₃)O] units (i-Pr) or n-propoxy units (Pr), ormixtures of EO and/or Pr and/or i-Pr units.

The dissolvable region may include at least one fluorosurfactantselected from nonionic fluorosurfactants, cationic fluorosurfactants,and mixtures thereof which are soluble or dispersible in aqueouscompositions, sometimes compositions which do not include furtherdetersive surfactants, or further organic solvents (e.g., in the case ofgels), or both. Suitable nonionic fluorosurfactant compounds are foundamong the materials presently commercially marketed under the tradenameFLUORAD (ex. 3M Corp.) Exemplary fluorosurfactants include those sold asFLUORAD FC-740, generally described to be fluorinated alkyl esters;FLUORAD FC-430, generally described to be fluorinated alkyl esters;FLUORAD FC-431, generally described to be fluorinated alkyl esters; and,FLUORAD FC-170-C, which is generally described as being fluorinatedalkyl polyoxyethlene ethanols.

An example of a suitable cationic fluorosurfactant compound has thefollowing structure: C_(n)F_(2n)+1 SO₂NHC₃H₆N+(CH₃)3I— where n˜8. Thiscationic fluorosurfactant is available under the tradename FLUORADFC-135 from 3M. Another example of a suitable cationic fluorosurfactantis F3-

(CF₂)_(n)—(CH₂)_(m)SCH₂CHOH—CH₂—N+R₁R₂R₃Cl—

wherein: n is 5-9 and m is 2, and R₁, R₂ and R₃ are —C—I₃. This cationicfluorosurfactant is available under the tradename ZONYL FSD (availablefrom DuPont, described as 2-hydroxy-3-((gamma-omega-perfluoro-C₆-C₂₀-alkyl)thio)-N,N,N-trimethyl-1-propyl ammonium chloride). Othercationic fluorosurfactants suitable for use in the present invention arealso described in EP 866,115 to Leach and Niwata, herein incorporated byreference. The fluorosurfactant selected from the group of nonionicfluorosurfactant, cationic fluorosurfactant, and mixtures thereof may bepresent in amounts of from 0.001 to 5% wt., preferably from 0.01 to 1%wt., and more preferably from 0.01 to 0.5% by weight.

The composition may comprise a nonionic surfactant. Essentially anyalkoxylated nonionic surfactants are suitable herein, for instance,ethoxylated and propoxylated nonionic surfactants. Alkoxylatedsurfactants can be selected from the classes of the nonionic condensatesof alkyl phenols, nonionic ethoxylated alcohols, nonionicethoxylated/propoxylated fatty alcohols, nonionic ethoxylate/propoxylatecondensates with propylene glycol, and the nonionic ethoxylatecondensation products with propylene oxide/ethylene diamine adducts.

The condensation products of aliphatic alcohols with from about 1 toabout moles of alkylene oxide, particularly ethylene oxide and/orpropylene oxide, are suitable for use herein. The alkyl chain of thealiphatic alcohol can either be straight or branched, primary orsecondary, and generally contains from about 6 to about 22 carbon atoms.Also suitable are the condensation products of alcohols having an alkylgroup containing from about 8 to about 20 carbon atoms with from about 2to about 10 moles of ethylene oxide per mole of alcohol.

Polyhydroxy fatty acid amides suitable for use herein are those havingthe structural formula R₂CONR₁Z wherein: R₁ is H, C₁-C₄ hydrocarbyl,2-hydroxyethyl, 2-hydroxypropyl, ethoxy, propoxy, or a mixture thereof,for instance, C₁-C₄ alkyl, or C₁ or C₂ alkyl; and R₂ is a C₅-C₃₁hydrocarbyl, for instance, straight-chain C₅-C₁₉ alkyl or alkenyl, orstraight-chain C₉-C₁₇ alkyl or alkenyl, or straight-chain C₁₁-C₁₇ alkylor alkenyl, or mixture thereof-, and Z is a polyhydroxyhydrocarbylhaving a linear hydrocarbyl chain with at least 3 hydroxyls directlyconnected to the chain, or an alkoxylated derivative (for example,ethoxylated or propoxylated) thereof. Z may be derived from a reducingsugar in a reductive amination reaction, for example, Z is a glycityl.

Suitable fatty acid amide surfactants include those having the formula:R₁CON(R₂)₂ wherein R₁ is an alkyl group containing from 7 to 21, or from9 to 17 carbon atoms and each R₂ is selected from the group consistingof hydrogen, C₁-C₄ alkyl, C₁-C₄ hydroxyalkyl, and —(C₂H₄O)_(x)H, where xis in the range of from 1 to 3.

Suitable alkylpolysaccharides for use herein are disclosed in U.S. Pat.No. 4,565,647 to Llenado, herein incorporated by reference, having ahydrophobic group containing from about 6 to about 30 carbon atoms and apolysaccharide, e.g., a polyglycoside, hydrophilic group containing fromabout 1.3 to about 10 saccharide units. Alkylpolyglycosides may have theformula: R₂O(C_(n)H_(2n)O)_(t) (glycosyl)_(x) wherein R₂ is selectedfrom the group consisting of alkyl, alkylphenyl, hydroxyalkyl,hydroxyalkylphenyl, and mixtures thereof in which the alkyl groupscontain from about to about 18 carbon atoms; n is 2 or 3; t is from 0 toabout 10, and x is from about 1.3 to about 8. The glycosyl may bederived from glucose.

Other suitable nonionic surfactants are food safe nonionic surfactants.Examples of food safe nonionic surfactants are sucrose esters, such assucrose cocoate available from Croda, and sorbitan esters, such aspolyoxyethylene(20) sorbitan monooleate from J. T. Baker andpolyoxyethylene(20) sorbitan monolaurate from Uniquema. Other examplesof food safe nonionic surfactants are given in Generally Recognized AsSafe (GRAS) lists, as described below.

The dissolvable region may comprise at least one alkyl polyglucoside(“APG”) surfactant. Suitable alkyl polyglucoside surfactants are thealkylpolysaccharides that are disclosed in U.S. Pat. No. 5,776,872 toGiret et al.; U.S. Pat. No. 5,883,059 to Furman et al.; U.S. Pat. No.5,883,062 to Addison et al.; and U.S. Pat. No. 5,906,973 to Ouzounis etal., which are all incorporated by reference. Suitable alkylpolyglucosides for use herein are also disclosed in U.S. Pat. No.4,565,647 to Llenado describing alkylpolyglucosides having a hydrophobicgroup containing from about 6 to about 30 carbon atoms, or from about 10to about 16 carbon atoms and polysaccharide, e.g., a polyglycoside,hydrophilic group containing from about 1.3 to about 10, or from about1.3 to about 3, or from about 1.3 to about 2.7 saccharide units.

Optionally, there can be a polyalkyleneoxide chain joining thehydrophobic moiety and the polysaccharide moiety. A suitablealkyleneoxide is ethylene oxide. Typical hydrophobic groups includealkyl groups, either saturated or unsaturated, branched or unbranchedcontaining from about 8 to about 18, or from about 10 to about 16,carbon atoms. Suitably, the alkyl group can contain up to about 3hydroxy groups and/or the polyalkyleneoxide chain can contain up toabout 10, or less than about 5, alkyleneoxide moieties. Suitable alkylpolysaccharides are octyl, nonyldecyl, undecyldodecyl, tridecyl,tetradecyl, pentadecyl, hexadecyl, heptadecyl, and octadecyl, di-, tri-,tetra-, penta-, and hexaglucosides, galactosides, lactosides, glucoses,fructosides, fructoses and/or galactoses. Suitable mixtures includecoconut alkyl, di-, tri-, tetra-, and pentaglucosides and tallow alkyltetra-, penta-, and hexaglucosides.

Suitable alkylpolyglycosides (or alkylpolyglucosides) have the formula:

R₂O(C_(n)H_(2n)O)_(t)(glucosyl)_(x)

wherein R₂ is selected from the group consisting of alkyl, alkylphenyl,hydroxyalkyl, hydroxyalkylphenyl, and mixtures thereof in which thealkyl groups contain from about to about 18, preferably from about 12 toabout 14, carbon atoms; n is about 2 or about 3, preferably about 2; tis from 0 to about 10, preferably 0; and x is from about 1.3 to about10, preferably from about 1.3 to about 3, most preferably from about 1.3to about 2.7. The glycosyl is preferably derived from glucose. Toprepare these compounds, the alcohol or alkylpolyethoxy alcohol isformed first and then reacted with glucose, or a source of glucose, toform the glucoside (attachment at the 1-position). The additionalglycosyl units can then be attached between their 1-position and thepreceding glycosyl units 2-, 3-, 4- and/or 6-position, preferablypredominantly the 2-position.

A group of alkyl glycoside surfactants suitable for use in the practiceof this invention may be represented by formula I below:

RO—(R²O)_(y)-(G)_(x)Z_(b)  I

wherein R is a monovalent organic radical containing from about 6 toabout 30 (preferably from about 8 to about 18) carbon atoms; R² is adivalent hydrocarbon radical containing from about 2 to about 4 carbonatoms; O is an oxygen atom; y is a number which has an average valuefrom about 0 to about 1 and is preferably 0; G is a moiety derived froma reducing saccharide containing 5 or 6 carbon atoms; and x is a numberhaving an average value from about 1 to 5 (preferably from 1.1 to 2); Zis O₂M¹, O₂CR³, O(CH₂), CO₂M¹, OSO₃M¹, or O(CH₂)SO₃M¹; R³ is (CH₂)CO₂M¹or CH═CHCO₂M¹; (with the proviso that Z can be O_(2l M) ¹ only if Z isin place of a primary hydroxyl group in which the primaryhydroxyl-bearing carbon atom, —CH₂OH, is oxidized to form a —CO₂M¹group); b is a number from 0 to 3x+1 preferably an average of from 0.5to 2 per glycosal group; p is 1 to 10, M¹ is H⁺ or an organic orinorganic cation, such as, for example, an alkali metal, ammonium,monoethanolamine, or calcium. As defined in Formula I, R is generallythe residue of a fatty alcohol having from about 8 to about 30 or about8 to about 18 carbon atoms.

Suitable alkylglycosides include, for example, APG 325 (a C₉-C₁₁ alkylpolyglycoside available from Cognis Corporation), APG 625 (a C₁₀-C₁₆alkyl polyglycoside available from Cognis Corporation), DOW TRITON CG110(a C₈-C₁₀ alkyl polyglyco-side available from Dow Chemical Company),AG6202 (a C₈ alkyl polyglycoside available from Akzo Nobel) GLUCOPON425N (a C₈-C₁₆ alkyl polyglycoside available from Cognis Corporation),GLUCOPON 215 (a C₈-C₁₀ alkyl polyglycoside available from CognisCorporation), GLUCOPON 225 (a C₈-C₁₀ alkyl polyglycoside available fromCognis Corporation) and ALKADET 15 (a C₈-C₁₀ alkyl polyglycosideavailable from Huntsman Corporation). A C₈ to C₁₀ alkylpoly-glucosideincludes alkylpoly-glucosides wherein the alkyl group is substantiallyC₈ alkyl, substantially C₁₀ alkyl, or a mixture of substantially C₈ andC₁₀ alkyl. Additionally, short chain APGs such as C₄ and/or C₆ ormixtures thereof may be suitable with the present invention.

The dissolvable region may include a builder, which can increase theeffectiveness of the surfactant. The builder can also function as asoftener, a sequestering agent, a buffering agent, or a pH adjustingagent in the composition. A variety of builders or buffers can be usedand they include, but are not limited to, phosphate-silicate compounds,zeolites, alkali metal, ammonium and substituted ammonium polyacetates,trialkali salts of nitrilotriacetic acid, carboxylates,polycarboxylates, carbonates, bicarbonates, polyphosphates,aminopolycarboxylates, polyhydroxy-sulfonates, and starch derivatives.Builders, when used, include, but are not limited to, organic acids,mineral acids, alkali metal and alkaline earth salts of silicate,metasilicate, polysilicate, borate, sulfates, hydroxide, carbonate(e.g., sodium carbonate), carbamate, phosphate, polyphosphate,pyrophosphates, triphosphates, tetraphosphates, ammonia, hydroxide,monoethanolamine, monopropanolamine, diethanolamine, dipropanol-amine,triethanolamine, and 2-amino-2-methylpropanol.

Other suitable buffers include ammonium carbamate, citric acid, andacetic acid. Mixtures of any of the above are also acceptable. Usefulinorganic buffers/alkalinity sources include ammonia, the alkali metalcarbonates and alkali metal phosphates, e.g., sodium carbonate, sodiumpolyphosphate. For additional buffers see WO 95/07971, which isincorporated herein by reference. Other preferred pH adjusting agentsinclude sodium or potassium hydroxide. The term silicate is meant toencompass silicate, metasilicate, polysilicate, aluminosilicate andsimilar compounds. Preferred buffers for both the dissolvable andnon-dissolvable regions of the shaped composition include carbonate,bicarbonate, sesquicarbonate and mixtures thereof.

The dissolvable region may comprise a water-soluble polymer. In oneembodiment; the dissolvable region of the composition can contain awater-soluble polymer. Examples of water-soluble polymer include, butare not limited to, polycarboxylate, sulfonated carboxylate,polysulfonate, polyyinylpyrrolidone (“PVP”), and mixtures thereof.

Examples of polycarboxylate include, but are not limited to, polymerswith sufficient carboxylate ions to achieve water solubility.Carboxylate ions may be derived from various monomers including acrylicacid, maleic acid and maleic anhydride. Copolymers of differentcarboxylate-containing monomers are also suitable as well as copolymerswith non carboxylate containing monomers such as methacrylate,acrylonitrile, styrene, ethylene, propylene, water-insolublepolyacrylate, acrylonitrile butadiene styrene, polystyrene and manyothers. Mixtures of carboxylate containing polymers can also be used.

Suitably, the molecular weight of the water-soluble polymer may bebetween about 1,000 to about 10,000 daltons, about 1,000 to about 8,000daltons, about 1,000 to about 6,000 daltons, about 1,000 to about 5,000daltons, about 1,000 to about 4,000 daltons, about 1,000 to about 2,000daltons, about 2,000 to about 10,000 daltons, about 2,000 to about 8,000daltons, about 2,000 to about 6,000 daltons, about 2,000 to about 5,000daltons, about 2,000 to about 4,000 daltons, about 3,000 to about 10,000daltons, about 3,000 to about 8,000 daltons, about 3,000 to about 6,000daltons, about 3,000 to about 5,000 daltons, about 3,000 to about 4,000daltons, about 4,000 to about 10,000 daltons, about 4,000 to about 8,000daltons, about 4,000 to about 6,000 daltons, about 5,000 to about 10,000daltons, about 5,000 to about 7,500 daltons, or about 7,500 to about10,000 daltons.

Suitably, the water-soluble polymer is present in an amount ranging fromabout 0.1% to about 60%, about 0.1% to about 50%, about 0.1% to about40%, about 0.1% to about 30%, about 0.1% to about 20%, about 0.1% toabout 15%, about 0.1% to about 10%, about 5% to about 60%, about 5% toabout 50%, about 5% to about 40%, about 5% to about 30%, about 5% toabout 20%, about 5% to about 10%, about 10% to about 60%, about 10% toabout 50%, about 10% to about 40%, about 10% to about 30%, about 10% to20%, about 20% to about 60%, about 20% to about 50%, about 20% to about40%, about 20% to about 30%, about 30% to about 60%, about 30% to about50%, about 30% to about 40%, or about 40% to about 60%.

The composition may also optionally contain a filler. In one embodiment,all regions of the shaped composition comprise a filler. In anotherembodiment, only the dissolvable region of the composition comprises afiller. In another embodiment, only the non-dissolvable region of thecomposition comprises a filler. In another embodiment, a third regioncomposition only comprises a filler.

Examples of fillers that can be used with the present invention include,but are not limited to, a carbonate, a bicarbonate, a sesquicarbonate, achloride, a sulfate, a phosphate, a silicate, borate, a nitrate, analuminate, a silica-aluminate, a hydroxide, or an oxide compound ofalkali metals, alkaline earths, aluminum, zinc and tin includinghydrates, mono, di and tribasic compounds, mixed salts, a borate, aclay, a zeolite, and mixtures thereof. Specific examples of fillersinclude, but are not limited to, sodium carbonate, potassium carbonate,zinc carbonate, calciumn carbonate, magnesium carbonate, sodiumbicarbonate, potassium bicarbonate, magnesium bicarbonate, sodiumsesquicarbonate, sodium chloride, sodium sulfate, zinc sulfate,magnesium sulfate, calcium sulfate, sodium phosphate, sodium aluminumphosphate, disodium hydrogen phosphate, sodium dihydrogen phosphate,nesosilicales, sorosilicates, cyclosilicates, inosilicates (single ordouble chain), phyllosilicates, tectosilicates, sodium silicate, borax,boric acid, diborates, triborates, tetraborates, metaborates, sodiumnitraite, potassium nitrate, calcium nitrate, magnesium nitrate, sodiumaluminate, potassion alumninate, tricalcium aluminate, alumina oxide,magnesium oxide, aluminum hydroxide, calcium hydroxide, magnesiumhydroxide, calcium hydroxide, calcium oxide, zinc oxide, tin dioxide,titanium dioxide, silica alumina, and zeolite A.

The dissolvable region may comprise one or more hydrotropes forsolubilizing the other components of the composition when contacted withwater. The hydrotrope solubilizing materials, when used, include, butare not limited to water soluble salts of low molecular weight organicacids such as the alkali metal (sodium and/or potassium) salts ofaromatic sulfonic acids, aliphatic sulfates, aliphatic sulfonates, andaliphatic carboxylates. Specific exemplary materials include, but arenot limited to, toluene sulfonate, cumene sulfonate, xylene sulfonate,naphthalene sulfonate, methyl naphthalene sulfonate, octyl sulfate,octyl sulftbnate, octanoic acid, decanoic acid, and combinationsthereof.

The dissolvable region may comprise at least one wetting agent. Wettingof surfaces and penetration into pores and crevices of an objectcontacting the sanitizing water stream can improve the sanitizingeffect. Examples of wetting agents include ingredients described in thesections for water soluble polymers, surfactants, and hydrotropes. Otherexample wetting agents include nonionic water soluble polymers. Theseinclude polymers of ethylene oxide, propylene oxide, copolymers, andmixtures thereof.

The dissolvable region may comprise at least one dispersant. Adispersant may be included to help remove soils and microorganisms fromarticles and surfaces. Examples of dispersants include ingredientsdescribed in the sections for water soluble polymers, surfactants,hydrotropes, and wetting agents.

The dissolvable region may comprise at least one penetrant. A penetrantincreases the rate at which the functional agent (e.g., hypochlorile ionor hypochlorous acid) interacts with a microorganism. For example,cationic surfactants may act as phase transfer agents for thehypochlorous acid or hypochlorite ion. Particular exemplary cationicsurfactants are alkyltrimethylammonium, alkylpryidinium, andalkylethylmorpholinium salts, in which the alkyl group preferablycontains about 4 to about 18 carbon atoms, most preferably about 12 toabout 16 carbon atoms. The alkyl chains may be linear or branched orcontain an aryl group. The counterion is preferably, but not limited to,chloride, sulfate, methylsulfate, ethylsulfate, or toluene sulfonate.

Other suitable cationic surfactants include dialkyldimethyl ammoniumsalts, in which the alkyl groups each contain about 4 to about 12 carbonatoms such as dioctyldimethylammonium chloride. Other suitable cationicsurfactants may have two quaternary ammonium groups connected by a shortalkyl chain such as N-alkylpentamethyl propane diammonium chloride. Inthe above cationic surfactants the methyl constituents can be completelyor partially replaced by other alkyl or aryl constituents such as ethyl,propyl, butyl, benzyl, and ethylbenzyl groups, for exampleoctyldimethylbenzyl ammonium chloride and tetrabutylammonium chloride.Cationic polymers may also function as phase transfer agents. Examplesinclude but are not limited to polymers and copolymers of alkenes withquaternary ammonium groups such as vinyl alkyl trimethylammonium, vinylN-alkyl pyridinium, and vinyl N-alkylmorpholinium. A preferred cationicpolymer is DADMAC, poly diallyl dimethyl ammonium chloride.

A chelating agent may be included in the composition. Exemplarychelating agents include complexing agents such as the amine oxides ofamino methylphosphonic acids (e.g. aminotri(methylene phosphonic acid)N-oxide and ethylenediamine tetra(methylene phosphonic acid)N,N′-dioxide), organophosphonates (e.g.1-hydroxyethylidene-1,1-diphosphonic acid, phosphonohydroxyacetic acid,and 2-phosphono-butane-1,2,4-tricarboxylic acid), organocarboxylates(e.g. dipicolinic acid, 2-oxa-1,3,4 butane tricarboxylate and2-oxa-1,1,3 propane tricarboxylate), and organo-sulfonates (e.g. sodiumxylene sulfonate and sodium methylnaphthalene sulfonate).

Various anionic or zwitterionic surfactants that may bind to cations andinhibit their precipitation are also suitable chelating agents.Preferred surfactants interact with calcium ions and may be classifiedas lime-scale dispersants. These include C6-C18 alkyl betaines (e.g.decylbetaine and cetylbetaine), C6-C18 acyl sarcosinates (e.g. sodiumlauroyl-sarcosinate), C6-C18 acyl C1-C6 alkyl taurates (e.g. sodiumcocoylmethyltaurate), and C6-C18 alkyl-iminodipropionates (e.g. sodiumlauryliminodipropionate), C6-C18 alkyl, aryl, or alkylaryl ethersulfates, C6-C18 alkyl, aryl, or alkylaryl ether methylsulfonates,C6-C18 alkyl, aryl, or alkylaryl ether carboxylates, sulfonatedalkyldiphenyloxides (e.g. sodium dodecyldiphenyloxide disulfonate), andmono or di esters of phosphoric acid with C4-C18 alkyl, aryl, alkylaryl,alkylether, arylether and alkylarylether alcohols (e.g. disodium octylphosphate).

Various polymers and oligomers are also suitable chelating agents. Theseinclude polycarboxylate polymers made from acrylic acid and maleic acid,optionally with copolymers of various olefins, methacrylate, styrene,methylvinylether, vinylpyrrolidone, alkenes with quaternary ammoniumgroups such as vinyl alkyl trimethylammonium, vinyl N-alkyl pyridinium,and vinyl N-alkylmorpholinium, etc. Sulfonate groups can be includedusing sulfonated styrene or other sulfonated alkenes.

Polysulfonated polymeric dispersants can also be made by sulfonatingvarious alkyl or aryl polymers. Sulfonated napthalene formaldehydecopolymers are also useful. Typically the water soluble polymer oroligomer will have 3 to about 10,000 monomer units, more preferablyabout 20 to about 2,000 monomer units. Combinations of polymers withcomplexing agents are often more effective than either agent alone.Thus, mixtures of chelating agents from two or more of the above classesmay be desired.

The dissolvable region may comprise at least one odor controlling agent.While many odors are effectively controlled by other ingredients in thecomposition, such as hypochlorite ion or hypochlorous acid, additionalingredients to control odors may be included. Examples of odorabsorbents include, but are not limited to starches, cyclodextrins,activated carbon, zinc ricinoleate, puffed borax, silica, silica gel,fumed silica, precipitated silica, alumina, clay, and zeolites.

The dissolvable region may include a fragrance. Fragrances can beincluded to improve the odor of the composition, the solution made bydissolving the composition in water, or the article, surface or areathat is contacted by this solution. Fragrances may be a single compoundsuch as linalool or a mixture of compounds.

Depending on the nature of the functional agent, the dissolving regionmay include a flavoring agent. Exemplary flavoring agent may include,but are not limited to, spices, seasonings, sour flavors, flavorenhancers, savory flavors, natural or artificial flavors, isoamylacetate, benzaldehyde, cinnamic aldehyde, ethyl propionate, methylanthranilate, allyl hexanoate, ethyl maltol, ethylvanillin, wintergreenoil (methyl salicylate), oil of peppermint, oil of sassafras(synthetic), oil of anise, glutamic acid salts, glycine salts, guanylicacid salts, isosinic acid salts, 5-ribonucleotide salts, acetic acid,ascorbic acid, citric acid, fumaric acid, lactic acid, malic acid,phosphoric acid, tartaric acid, or combinations thereof.

In addition to a flavoring agent, the composition of the dissolvingregion can include a sweetener. Suitable sweeteners include, but are notlimited to, various natural and/or synthetic sweeteners (e.g., sugaralcohols) such as saccharin, sucralose, maltitol, erythritol, cyclamate,glucose, lactose, fructose, stevia, aspartame, sucralose, neotame,acesulfame potassium, dextrose, sucrose, levulose (i.e., fructose),xylitol, maltodextrin, and/or sorbitol.

Colorants may be used to color one or more parts of the shapedcomposition, or they may be used to color the stream of water resultingafter the dissolving portion is dissolved into the stream of water. Forexample any food coloring—red, green, blue, etc. may be included. Otherexamples of colorants include inorganic pigments such as cobalt blue,ultramarine blue, permanganate and chromate. Organic dyes and pigmentsincluding substituted phthalocyanines, substituted anthraquinones,substituted stilbenes, and substituted indanthrones may be suitable.Some specific examples of suitable colorants include, but are notlimited to, Pigment Blue 14, Pigment Blue 15, Pigment Blue 16, PigmentBlue 28, Pigment Green 7, Pigment Green 36, Pigment Yellow 108, DirectYellow 6, Direct Yellow 28, Direct Yellow 29, Direct Yellow 39, DirectYellow 96.

The dissolving region of the shaped composition may include a corrosioninhibitor. The composition may contain precipitated or fumed colloidalsilica or a silicate salt with the molar ratio of SiO₂ to Na₂O of 1-3 toprevent dulling of metal faucets, sinks, or other appliances. Otherexamples of suitable corrosion inhibitors include, but are not limitedto zinc oxide, zinc phosphate, other phosphate salts, ascorbic acid,cinnamaldehyde, nitrites, dimethylethanolamine, phenylenediamine,hexamine, benzotriazole, benzalkonium chloride, derivatives of tannicacid, morpholine, imidazoline, aliphatic amines, borax, salts of fattyacids, salts of aliphatic or aromatic sulfonic acids, and mixturesthereof.

A viscosity modifier may be included within the dissolving region.Viscosity modifiers can be included to modify the rheology of thetreated stream of water. Suitable thickening agents include, forexample, natural and synthetic gums or gum like materials such as gumtragacanth, carboxymethylcellulose, polyvinyl pyrrolidone, and/orstarch. Linear or branched polycarboxylate polymers are also suitable,especially various high molecular weight polycarboxylates with multiplechains that are linked together as constituents on a multi-functionalmolecule to create a star-like molecule. Inorganic thickeners includingalumina, various clays, organo-modified clays, aluminates and silicatesare also suitable thickening agents.

Thickening can also be achieved using combinations of oppositely chargedor psuedo-charged surfactants or combinations of surfactants andpolymers. Examples include combinations of anionic surfactants such asfatty acids, alkyl sulfates, or alkyl sulfonates with cationic polymerssuch as DADMAC, polyallyldimethylammonium chloride, combinations ofcationic or psuedo cationic surfactants such as alkyl pyridinium salts,alkyltrimethyl ammonium salts, alkyldimethylamine oxides, alkylbetaines, or acylsarcosinates with anionic polymers, anionicsurfactants, arylsulfonates, or substituted aryl sulfonates, andsurfactants such as alkylether sulfates that thicken by balancing thealkyl chain length with the number of ether linkages.

A vitamin or mineral may be included in the dissolving region. Potablewater containing vitamins or minerals prepared by flowing a stream ofwater over the dissolvable composition may provide a health benefit tothe consumer. Exemplary vitamins and minerals include, but are notlimited to, Vitamin A, Vitamin B1, Vitamin B2, Vitamin B3, Vitamin B5,Vitamin B6, Vitamin B7, Vitamin B9, Vitamin B12, Vitamin C, Vitamin D,Vitamin E, and mixtures thereof. Precursors that naturally producevitamins during consumption are also suitable. Examples include, but arenot limited to, beta carotene, tryptophan and mixtures thereoflExemplary minerals include, but are not limited to, salts of potassium,chlorine, sodium, calcium, phosphorous, magnesium, zinc, iron,manganese, copper, iodine, selenium, molybdenum, and mixtures thereof.

A foam booster may be included within the dissolving region. Foam can becreated by flowing water over the dissolvable region of the shapedcomposition. The effect of a foam booster can be enhanced by theinclusion of a surfactant. Certain combinations of surfactants willsynergistically increase the amount and longevity of the foam. Inaddition other ingredients such as water soluble polymers and viscositymodifiers can increase the amount or longevity of the foam. Theformulation can also include a foam booster to increase the amount orlongevity of foam. Exemplary foam boosters include, but are not limitedto, fatty acid amides, alkoxylated fatty acid amides, fatty acid amidesof alkanolamines, fatty acid amides of alkoxylated alkanolamines, andfatty acid amides of alkanolamide esters.

The composition may contain a defoamer within the dissolving region.Examples of defoamers or foam control agents include, but are notlimited to, alkoxylated alcohols capped with aliphatic ethers,polyglycol ethers, polyglycol esters, polyoxyethylene-polyoxypropyleneblock copolymers, silica, fumed silica, silicones, aminosilicones,silicone blends, and/or silicone/hydrocarbon blends and mixturesthereof.

A variety of other functional ingredients can also be included dependingon the intended use of the composition. Examples of other functionalingredients include, but are not limited to, stain and soil repellants,fluorescent whitening agents, enzymes, cloud point modifiers,anti-microbial agents, sporulation agents, catalysts or activators forhypochlorite ion or hypochlorous acid, and therapeutic agents.

The compositions optionally contain one or more of the followingadjuncts: desiccants, lubricants, glidants, agglomeration aids, binders,corrosion inhibitors, electrolytes, solubilizing agents, stabilizers,solid processing aids, preservatives, free radical inhibitors, UVprotection agents, anti-oxidants, and other polymers. Binders, whenused, include, but are not limited to, celluloses, starches, gums, andsynthetic polymers. Solid processing aids, when used, include, but arenot limited to, flow aids, lubricants, anti-static agents, and glidants.Electrolytes, when used, include calcium, sodium and potassium chloride.

Preservatives, when used, include, but are not limited to, mildewstat orbacteriostat, methyl, ethyl and propyl parabens, phosphates such astrisodium phosphate, short chain organic acids (e.g. acetic, lacticand/or glycolic acids), bisguanidine compounds (e.g. DANTAGARD and/orGLYDANT) and/or short chain alcohols (e.g. ethanol and/or IPA). Themildewstat or bacteriostat includes, but is not limited to, mildewstats(including non-isothiazolone compounds) including KATHON GC, a5-chloro-2-methyl-4-isothiazolin-3-one, KATHON ICP, a2-methyl-4-isothiazolin-3-one, and a blend thereof, and KATHON 886, a5-chloro-2-methyl-4-isothiazolin-3-one, all available from Rohm and HaasCompany; BRONOPOL, a 2-bromo-2-nitropropane 1,3 diol, from Boots CompanyLtd., PROXEL CRL, a propyl-p-hydroxybenzoate, from ICI PLC; NIPASOL M,an o-phenyl-phenol, Na⁺ salt, from Nipa Laboratories Ltd., DOWICIDE A, a1,2-Benzoisothiazolin-3-one, from Dow Chemical Co., NIPACIDES fromClariant, and IRGASAN DP 200, a 2,4,4′-trichloro-2-hydroxydiphenylether,from Ciba-Geigy A.G.

The composition may optionally contain a cross-linked water-swellablepolymer. In one embodiment, only the dissolvable region of thecomposition contains a cross-linked water-swellable polymer. In anotherembodiment, only the non-dissolvable region of the composition containsa cross-linked water-swellable polymer. In another embodiment, thedissolvable and non-dissolvable regions of the composition both containa cross-linked water-swellable polymer. Examples of water-swellablepolymers include, but are not limited to, cross-linked polycarboxylate,cross-linked polysulfonate, cross-linked carboxymethylcellulose,cross-linked PVP, cross-linked carboxymethyl cellulose, cellulose,sodium carboxymethylcellulose and mixtures thereof.

Suitably, the molecular weight of the water-swellable polymer may bebetween about 1,000 to about 10,000 daltons, about 1,000 to about 8,000daltons, about 1,000 to about 6,000 daltons, about 1,000 to about 5,000daltons, about 1,000 to about 4,000 daltons, about 1,000 to about 2,000daltons, about 2,000 to about 10,000 daltons, about 2,000 to about 8,000daltons, about 2,000 to about 6,000 daltons, about 2,000 to about 5,000daltons, about 2,000 to about 4,000 daltons, about 3,000 to about 10,000daltons, about 3,000 to about 8,000 daltons, about 3,000 to about 6,000daltons, about 3,000 to about 5,000 daltons, about 3,000 to about 4,000daltons, about 4,000 to about 10,000 daltons, about 4,000 to about 8,000daltons, about 4,000 to about 6,000 daltons, about 5,000 to about 10,000daltons, about 5,000 to about 7,500 daltons, and about 7,500 to about10,000 daltons.

Suitably, the water-swellable polymer is optionally present in an amountranging from about 0.1% to about 60%, about 0.1% to about 50%, about0.1% to about 40%, about 0.1% to about 30%, about 0.1% to about 20%,about 0.1% to about 15%, about 0.1% to about 10%, about 5% to about 60%,about 5% to about 50%, about 5% to about 40%, about 5% to about 30%,about 5% to about 20%, about 5% to about 10%, about 10% to about 60%,about 10% to about 50%, about 10% to about 40%, about 10% to about 30%,about 10% to 20%, about 20% to about 60%, about 20% to about 50%, about20% to about 40%, about 20% to about 30%, about 30% to about 60%, about30% to about 50%, about 30% to about 40%, about 40% to about 60%.

As explained above, the provided concentration of functional agent ispreferably substantially uniformly delivered over the life of the shapedcomposition. In one embodiment, any variability within the deliveredconcentration over the life of the shaped composition is not more than±about 50%, more preferably no more than ± about 30%, and mostpreferably no more than ±about 20%. In one embodiment, the life of theshaped composition may refer to the time period between when 90% of theinitial mass of the dissolvable region of the shaped composition remainsand when 10% of the initial mass of the dissolvable region of the shapedcomposition remains.

For example, there may be a greater variability during a “start up”period when the mass is reduced from 100% to 90%. Similarly, once only10% of the dissolvable region remains, there may also be a greatervariability, and the shaped composition may typically be replaced oncereaching 10% of the initial mass of the dissolvable region (e.g., theindicator feature of FIG. 2A or 2B may indicate a need to replace theshaped composition).

Calcium hypochlorite, magnesium hypochlorite, and mixtures thereof areparticularly preferred as anti-microbial food-safe sanitizing agents.For example, calcium hypochlorite is relatively inexpensive, provides ahighly concentrated source of hypochlorite, and does not exhibit astrong “bleach” type odor upon dissolution into the stream of water attypically effective concentrations. In one embodiment, the concentrationof hypochlorite dissolved within the stream of water is typicallybetween about 25 ppm and about 200 ppm, more typically between about 25ppm and about 100 ppm, and most typically between about 25 ppm and about75 ppm (e.g., about 50 ppm).

In one embodiment, the sanitizing rinse may be non-invasive and gentle.For example, all that may be required is contact (e.g., no scrubbingrequired) with the sanitizing rinse and a period of time for thesanitizing agent to work. For example, the concentration of hypochloriteor other sanitizing agent may be sufficient (e.g., at about 50 ppm) so,that contacting produce, hands, hard surfaces, or other surfaces withthe water stream and then waiting a short period of time (e.g., lessthan about 1 minute, less than about 30 seconds, about 15 seconds, orabout 10 seconds) is sufficient to sanitize the contacted surface. Itmay not be necessary to rinse the desired object for 10 seconds or more,but simply to contact the object with the sanitizing rinse, and thenallow it to sit for at least about 10 seconds to be sanitized. Suchembodiments are greatly advantageous over dunking methods, in whichsubmerged dunking contact of 20 minutes or more may be required.

In one embodiment, the geometry of the shaped composition including itsoverall shape (e.g., a cylinder), the aspect ratio of the provided shape(e.g., greater than about 1, preferably at least about 2, morepreferably at least about 3, more preferably at least about 4, and morepreferably at least about 5), and the inclusion of the substantiallynon-dissolvable region all serve as means for providing uniformdissolution of the dissolvable region or layer in a stream of water. Inone embodiment, particularly where the aspect ratio is relatively high(e.g., at least about 3), no non-dissolvable region may be present.

In one embodiment, the shaped composition, including both dissolvableregion 102 and non-dissolvable region 104 may comprise a hollowcylinder. The geometry of the shaped composition including its overallshape (e.g., a hollow cylinder), the aspect ratio of the provided shape(e.g., greater than about 0.01, preferably at least about 0.05, morepreferably at least about 0.1, more preferably at least about 0.5, morepreferably at least about 0.75, more preferably at least about 1), andthe inclusion of the substantially non-dissolvable region all serve asmeans for providing uniform dissolution of the dissolvable region orlayer in a stream of water.

An exemplary hollow cylinder is shown in FIG. 3. When providing a hollowcylinder 200, dissolution of the dissolvable region 202 may be achievedthrough diameter reduction, rather than predominantly through heightreduction along top surface 206. The stream of water can be contactedwith the outer peripheral surface 210, inner peripheral surface 210′, orboth surfaces 210 and 210′. In the embodiment shown in FIG. 3, anon-dissolvable region 204 may be provided adjacent bottom surface 208.

Where dissolution occurs principally along the peripheral surfaces,substantial uniformity of dissolution may be achieved through geometricconsiderations. For example, in order that the majority of the exteriorsurface area of the hollow cylinder 200 is located along the peripheralsurface, the hollow cylinder will preferably have an aspect ratio wherethe height is greater than the diameter. For example, the illustratedconfiguration of FIG. 3 includes a height that is about 1.5 times theoutside diameter.

When dissolving through a mechanism of diameter reduction, one willreadily appreciate that the peripheral surface area 210 decreases as theoutside diameter is reduced. This changing of the peripheral surfacearea 210 is offset by providing a hollow cylinder in which dissolutionoccurs simultaneously along both the outside peripheral surface 210 andthe inside peripheral surface 210′, because the surface area of theinside periphery 210′ increases while that of the outside periphery 210decreases. Together, the total surface area remains substantiallyconstant.

As will be readily apparent, the preference of ratio of the cylinderdiameter to height may thus be opposite that of the embodiment shown inFIGS. 1 and 2. In other words, in hollow cylinder embodiments, it may bepreferred to provide ratios of height to diameter that are greater thanabout 1, rather than ratios of diameter to height that are greater thanabout 1. For a hollow cylinder, the ratio of height to diameter maypreferably be at least about 1, at least about 1.5, at least about 2, atleast about 3, at least about 4, or at least about 5. Similarly, theratio of diameter to height may preferably be not greater than about 1,not greater than about 0.67, not greater than about 0.5, not greaterthan about 0.33, not greater than about 0.25, not greater than about 0.2as defined in FIG. 13.

Substantially non-dissolvable region 204 may be particularly beneficialwhere the diameter dimension approaches or is greater than that of theheight for similar reasons as explained relative to the cylindricalconfiguration of FIGS. 1-2. In one embodiment, a non-dissolvable regionmay be provided to protect and cover the top surface 206, the bottomsurface 208, or both. In embodiments where dissolution occurssimultaneously along both outside periphery 210 and inside periphery210′, a non-dissolvable region may not be needed.

Additional hollow cylinder configurations are shown in FIGS. 14-17. Forexample, FIG. 14 shows a hollow cylinder dissolvable composition 400comprised entirely of a dissolvable region 402, so that nonon-dissolvable region is included. FIG. 15 shows a hollow cylinderconfiguration 500 similar to that shown in FIG. 3, but in which theinsoluble layer 504 completely covers the hole of one end of the hollowcylinder 502 so as to prevent water from flowing therethrough. Water isstill able to flow along the outside peripheral surface 510 of thehollow cylinder 502, dissolving the dissolvable region 502 throughdiameter reduction of the outside diameter surface 510.

FIG. 16 shows a hollow cylinder 600 with a dissolvable layer 602 inbetween two insoluble non-dissolvable layers 604 and 604′. Thenon-dissolvable layers 604 and 604′ do not cover either end of thecenter hole 609 of the cylinder 602 so as to allow water flow along theinside diameter 610′, the outside diameter 610, or both. Anotherembodiment may include a covering of a non-dissolvable region thatcovers the outside peripheral surface 610 associated with the outsidediameter of the hollow cylinder, so that dissolution occurs only alongthe inside diameter peripheral surface 610′.

FIG. 17 shows a hollow cylinder 700 with a dissolvable layer 702 and onenon-dissolvable layer 704 covering the top surface of the dissolvablelayer 702 (i.e., similar to if the hollow cylinder of FIG. 3 were turnedupside down). The central hole 709 of the hollow cylinder 700 is notcovered or blocked so as to allow water flow along the inside diameterperipheral surface 710′. Of course, water flow is also or alternativelypossible along outside diameter peripheral surface 710.

In one embodiment, the functional agent comprises a hypochlorite. Thehypochlorite comprises between about 20% and about 100% by weight of thedissolvable region or layer of the shaped composition. In anotherembodiment, the hypochlorite comprises between about 50% and about 100%by weight of the dissolvable region. In one embodiment, the hypochloritecomprises between about 55% and about 100% of the dissolvable region byweight. In another embodiment, the hypochlorite comprises between about60% and about 100% by weight of the dissolvable region.

In another embodiment, the hypochlorite comprises between about 70% andabout 90% by weight of the dissolvable region. In another embodiment,the hypochlorite comprises between about 60% and about 70% by weight ofthe dissolvable region. In another embodiment, the hypochloritecomprises between about 70% and about 100%, about 80% to about 100%, orabout 90% to about 100% of the dissolvable region or layer of the shapedcomposition.

Additional components may be included within the dissolvable region orlayer of the shaped composition, for example, to aid in maintaininguniform delivery of the hypochlorite or other functional agent to thestream of water, to increase or decrease the rate of dissolution of thefunctional agent, and/or to provide other functional or active agents tothe water stream. For example, carbonates (e.g., potassium carbonate),sulfates, sodium chloride and/or polyacryates may be included to adjustthe solubility of a hypochlorite functional agent, which increases ordecreases the hypochlorite concentration for any given flow rate of thewater stream.

Where the hypochlorite comprises calcium hypochlorite, and a carbonateis also included, the inclusion of a polyacrylate may aid insolubilizing calcium carbonate. This can prevent or minimize anyprecipitation and encrustation of calcium carbonate on the faucet, onthe device attachable thereto, or within the sink, etc. Exemplarypolyacrylates may include ALCOSPERSE 149D, AQUATREAT AR-978, AQUATREATAR-980, and ACUSOL 445ND. In one embodiment, the level of polyacrylateprovided within the water stream is between about 1 ppm and about 50ppm, more typically between about 5 ppm and about 30 ppm, most typicallybetween about 10 ppm and about 20 ppm (e.g., about 15 ppm).

In one embodiment, the shaped composition may further include a thirdregion. An example of such an embodiment is shown in FIG. 4. FIG. 4shows a shaped composition 300 including a third region 312 that isdissolvable in a manner similar to region 302, but which may contain oneor more components that are incompatible with dissolvable region 302.Such a region may be separated from dissolvable region 302 bysubstantially non-dissolvable region 304. Dissolvable region 302includes a top surface 306 and peripheral surface 310. Bottom surface308 is covered by non-dissolvable region 304, which also covers topsurface 316 of third region 312. Third region 312 similarly includes anexposed bottom surface 318 and peripheral surface 314. Of course, onemay flip the shaped composition over so that third region 312 isdisposed at the “top” and dissolvable region 302 is disposed at thebottom.

In one embodiment, such an additional region or layer 312 may include anacid or acid salt for reaction with the hypochlorite so as to formhypochlorous acid. For example, hypochlorous acid is an excellentantimicrobial sanitizing functional agent.

Exemplary acids and salts suitable for use within the second dissolvableregion (e.g., third region 312) include, but are not limited to, organicacids, carboxylic acids, dicarboxylic acids, phosphoric acids,phosphonic acids, sulfuric acids, sulfonic acids, saturated fatty acids,unsaturated fatty acids, and inorganic acids. Suitable examples include,but are not limited to, acetic acid, toluene sulfonic acid, xylenesulfonic acid, ocatanoic acid, phosphonic acid(1-hydroxyethylidene)bis-dodecylbenzene sulfonic acid,octenylbutanedioic acid, n-carboxylic acids (C₆-C₁₂), decanoic acid,ethylenediamine disodium salt, lactic acid, 1,2-ocatanesulfonic acid,2-sulfino-1-octanesulfonic acid, 2,6-pyridinecarboxylic acid, sulfuricacid, hydrochloric acid, citric acid, sorbic acid, succinic acid, adipicacid, phosphoric acid, phosphoric acid monosodium salt, orthophosphoricacid, pyrophosphoric acid, trimetaphosphoric acid, tripolyphosphoricacid, polyphosphoric acids, tetrapolyphosphoric acid, polyacrylic acid,ascorbic acid, sodium bicarbonate, calcium chloride, humic acid, fumaricacid, lauric acid, palmitic acid, myristic acid, stearic acid, arachidicacid, behenic acid, lignoceric acid, cerotic acid, myristoleic acid,paInitoleic acid, sapienic acid, oleic acid, linoleic acid, α-linolenicacid, arachidonic acid, eicosapentaenoic acid, crucic acid,docosahexaenoic acid, sodium bisulfate (an acid salt), or mixturesthereof.

Third region 312 may of course include other components described aboverelative to the other regions. For example, region or layer 312 mayinclude one or more of a builder, a surfactant, a water soluble polymer,an insoluble salt dispersant, a fragrance, or a colorant as describedherein. Examples of insoluble salt dispersants include ingredientsdescribed in conjunction with the disclosure of builders, water solublepolymers, hydrotropes, cross-linked water swellable polymers,surfactants, fillers, and chelating agents.

In one example, the second dissolvable region includes one or more acidsin a sufficient concentration to neutralize any alkaline substances andform hypochlorous acid from the hypochlorite present within the firstdissolvable region. In one example, the two dissolvable regions are ofapproximately equal mass and/or volume (e.g., providing about a 1:1mixing ratio) and are configured to dissolve at a rate appropriate tothe desired ratio.

Other components may be included to adjust the solubility of thedissolvable regions or layers. Suitable solubility adjusting agentsinclude, but are not limited to silica, hydrophobic silica, hydrophobicclay, phosphates, chlorides, polysiloxane compounds, sulfates, calciumsulfate, sodium sulfate, hydroxides, calcium hydroxide, magnesiumhydroxide, waxes, resins, cellulose and cellulosic materials (e.g.,hydroxypropyl cellulose), polyolefins, polyethylene, oxidizedpolyethylene, calcium stearate, magnesium stearate, sodium stearate,zinc stearate, fatty acids (e.g., lauric acid, palmitic acid, stearicacid, etc.), silicone, polydimethyl siloxane, dimethicone,cyclodimethicone, hexamethyldisiloxane, magnesium aluminum silicate,sodium magnesium silicate, calcium carbonate, butyl stearate, calciumsilicate, dolomite, magnesium carbonate, sodium carbonate, magnesiumoxide, magnesium oxide silicate, talc, magnesium sulfate, mineral oil,castor oil, and mixtures thereof. Polyacrylates (e.g., sodiumpolyacrylate) may be included to increase the rate of dissolution, aswell as aiding in dispersion of the functional agent. Typically, eachindividual solubility adjusting agent preferably comprises no more thanabout 20% by weight of the dissolving region composition.

In one embodiment, a mixture of adipic and lauric acid is employed inthe second dissolvable region. The adipic acid may comprise betweenabout 80% and about 90% of the mixture by weight, while the lauric acidmay comprise between about 10% and about 20% of the mixture by weight(e.g., about an 85/15 mixture).

Inclusion of an acid containing layer or region lowers the pH of theresulting water stream. For example, without any such acid, ahypochlorite solution may be very slightly basic (e.g., a pH of about7.5), while with the addition of the acid, the water stream may be veryslightly acidic (e.g., a pH of about 6.5).

Substantially non-dissolvable region or layer 104 may comprise anysuitable material that is less soluble than region 102, and preferablydoes not dissolve to any substantial degree upon exposure to water.Exemplary materials include, but are not limited to, cementitiousmaterials, polymers, inorganic materials, fatty acids or their salts,and mixtures thereof. Exemplary cementitious materials include, but arenot limited to, Portland cement, hydraulic cement, hydraulic cementblends, Pozzolan-lime cement, supersulfated cement, calcium aluminatecement, calcium sulfoaluminate cement, geopolymer cement, magnesiumoxychloride, magnesium oxysulfate, plaster of Paris, and mixturesthereof. In one embodiment, the non-dissolvable region or layer may befree of cementitious materials (e.g., it may be formed of one or moreother classes of non-dissolvable materials).

Exemplary polymer materials include, but are not limited to, waxes(e.g., carnauba wax), resins, natural polymers, phenol resins,polyethylene vinyl acetate, polyolefins, polyamides, polyesters,cellulose, polymers formed from styrene block copolymers precursors,polycaprolactone, fluoropolymers, silicone rubbers, polypyrrole,polyalkylsiloxanes, alkyl polyesters, polyvinyl chloride,urea-formaldehyde resins, polymethyl methacrylate, epoxy adhesives,nylon, polyfluorocarbons, melamine-formaldehyde, polyurethane,polycarbonate, polyimide resins, hydrogels, silicones, polyester,polyethylene, polypropylene, and mixtures thereof. In one embodiment,the non-dissolvable region or layer may be free of polymer materials(e.g., it may be formed of one or more other classes of non-dissolvablematerials).

Exemplary inorganic materials include, but are not limited to, hydroxideor oxide compounds of alkaline earth metals, alkaline earth sulfates(e.g., calcium sulfate, magnesium sulfate, and mixtures thereof),alkaline earth phosphates (e.g., calcium phosphate), silicates, borate,aluminate, silica-aluminate, clays, zeolites including hydrates, mono,di and tribasic compounds, fiberglass, and mixtures thereof. Exemplaryhydroxides or oxides of alkaline earth metals include, but are notlimited to, magnesium oxide, magnesium hydroxide, calcium hydroxide,calcium oxide, and mixtures thereof. Substantially insoluble oxides ofother metals may also be used (e.g., zinc oxide). In one embodiment, thenon-dissolvable region or layer may be free of inorganic materials(e.g., it may be formed of one or more other classes of non-dissolvablematerials).

Exemplary substantially non-dissolvable fatty acid and fatty acid saltmaterials include, but are not limited to, fatty acids (e.g., stearicacid, palmitic acid, and mixtures thereof), alkaline or alkaline earthfatty acid salts (e.g., salts of stearates or palmitates) such ascalcium stearate, magnesium stearate, sodium stearate, and mixturesthereof. Fatty acids (e.g., stearic acid, palmitic acid or other fattyacids) or their salts may include a carbon content of up to about 50carbon atoms. Such fatty acids may be present within the dissolvablelayer (e.g., lauric acid included in Example 29 below).

Where such is the case, the material of the non-dissolvable layer willbe substantially less soluble in the stream of water than the fatty acidincluded within the dissolvable region. In other words, while thesubstantially non-dissolvable region or layer may be somewhat soluble inwater, the dissolvable region or layer will have a substantially greatersolubility in water so as to dissolve, leaving the non-dissolvableregion or layer substantially intact at the end of the useful life ofthe shaped composition. In one embodiment, the non-dissolvable region orlayer may be free of fatty acid or fatty acid salt materials (e.g., itmay be formed of one or more of other classes of non-dissolvablematerials).

Many of the materials described above for use as solubility adjustingagents within the dissolvable region or layer may also be suitable foruse within the substantially non-dissolvable region or layer. Similarly,many of the substantially non-dissolvable materials describedimmediately above may be suitable for use as solubility adjustingagents.

In one embodiment, the dissolvable region(s) comprise the majority ofthe shaped composition. For example, the dissolvable region or regions(e.g., where an acid containing layer or region is provided) maycomprise about 55% to about 99% of the shaped composition by weightand/or volume. The non-dissolvable region may comprise a relatively thinlayer that covers and protects the bottom surface 108 of dissolvableregion 102. Where an acid containing region is also provided, thenon-dissolvable region may advantageously be sandwiched between thedissolvable regions so that the bottom surface of one dissolvable regionand the top surface of the other dissolvable region are covered andprotected by the non-dissolvable region or layer. Such an embodiment mayallow the stream of water to contact the top surface and flow over theperipheral surface of the dissolvable layer or region, and then contactthe bottom surface of the second dissolvable layer or region.

The various layers or regions of the shaped composition may be attachedto one another by any suitable mechanism. For example, attachment may beby mechanical means (e.g., the non-dissolvable region or layer maymechanically interlock with the dissolvable layer), by an adhesive(e.g., any type of glue, including a hot melt thermoplastic adhesive),or any other suitable attachment mechanism. Various suitable mechanismswill be apparent to one of skill in the art in light of the presentdisclosure.

In one embodiment, the shaped composition is relatively simple, and mayfunction to produce an antimicrobial sanitizing rinse that is food safeby simply contacting the top surface of the dissolvable region with astream of flowing water (e.g., from a kitchen, bathroom, or laundryfaucet). The shaped composition may be retained within afaucet-attachable device configured to easily attach over the dispensingend of a faucet and deliver water from the faucet so as to contact theshaped composition. In one embodiment, the faucet attachable device mayinclude a hinge or other mechanism to allow a portion of the deviceretaining the shaped composition to be easily moved or rotated out ofthe path of the stream of water, when normal tap water without thefunctional agent is desired.

The shaped composition is relatively simple, and may include no siphons,valves, floats, feeding systems or even monitoring devices. Theuniformity of the concentration of functional agent (e.g., ahypochlorite) is delivered through the geometry of the shapedcomposition, as well as the components included within the dissolvableregion or portion that may aid in adjusting (e.g., lowering) thesolubility or rate of dissolution of the functional agent. In oneembodiment, the dissolvable layer or region is not effervescent. Ofcourse, the non-dissolvable region is not effervescent as well. Inanother embodiment, the dissolvable layer or region and thenon-dissolvable layer or region is not effervescent. In one embodiment,the shaped composition may be contained within a cage or cartridge thatis inserted within the faucet attachable device. Additional details ofan exemplary faucet attachable device are disclosed in a patentapplication entitled FAUCET MOUNTABLE WATER CONDITIONING DEVICE, filedthe same day as the present application and bearing attorney docketnumber 600.84, which is incorporated by reference in its entirety.

The shaped composition may be sized so as to be replaceable after anappropriate time period. For example, the shaped composition may have alife between about 1 day and about 2 months, between about 2 days andabout 1 month, or between about 3 days and about 2 weeks based on anaverage water flow of about 1.5 gallons per minute, a desiredhypochlorite concentration of about 50 ppm, at about 4 uses per day, andabout 3 minutes per use. Stated another way, a cylindrical shapedcomposition having a dissolvable layer volume of about 10 cm³ may besufficient based on the above usage so that about 8 to 9 tablets wouldbe required each month. Such a 10 cm³ tablet may have a diameter ofabout 4 cm and a height of about 0.75 cm.

One of skill in the art will appreciate that a wide variety offunctional agents may be incorporated within the dissolvable layer orregion. For example, various functional agents may include, but are notlimited to, an antimicrobial sanitizing agent, a pH adjusting agent, asurfactant, a hydrotrope, a wetting agent, a mineral, a vitamin, apenetrant, a chelating agent, an odor masking agent, an odor absorbingagent, a colorant, a fluorescent whitening agent, a flavoring agent, afragrance, a sweetener, a potentiator, a sporulation agent, a corrosioninhibitor, a therapeutic agent, a viscosity modifier, a foam stabilizer,a foam booster, a defoamer, a stain and soil repellent, an enzyme, acloud point modifier, a dispersant, a catalyst, an activating agent, awater softening agent, or mixtures thereof.

EXAMPLES

FIG. 5 shows various exemplary tablets 1-16 that were actually made inorder to demonstrate the effect of various additives on dissolutionrate. The results relative to effect on dissolution are presented inFIGS. 6-8. Each cylindrical tablet had a mass of about 10 g and about5.5 cm³. Each tablet had a diameter of about 3 cm and a height of about0.6 cm. The results show that magnesium hydroxide, calcium sulfate,sodium carbonate, and magnesium sulfate act to slow dissolution of thecalcium hypochlorite. Such components may be used to tailor thedelivered concentration of hypochlorite within the treated stream ofwater to an effective, desired level (e.g., about 50 ppm).

In contrast, calcium carbonate acts to increase the rate of dissolutionof the calcium hypochlorite. The amount of calcium hypochlorite withineach example ranged from 75% by weight to 95% by weight, while thevarious salts were included at 5% by weight, if at all.

The tablets were also provided with differing surface textures, fromvery rough to smooth including three intermediate textures of rough,textured, and slightly textured in order to study the effect of suchtexturing. With respect to texturing, it was found that a smooth surfacewas preferred for providing more uniform dissolution of the dissolvablelayer, and that texturing may cause water to pool or otherwise build upon the tablet surface, leading to uneven disintegration of thedissolvable layer of the shaped composition.

Additional examples 1-31 are presented below. Examples 1-14 include ahypochlorite antimicrobial sanitizing functional agent in thedissolvable region or layer.

Example #1

% wt. of dissolvable Dissolvable region region calcium hypochlorite 100%% wt. of Non-dissolvable non-dissolvable region region magnesium oxide100%

Example #2

% wt. of dissolvable Dissolvable region region calcium hypochlorite 100%% wt. of non- Non-dissolvable dissolvable region region vermiculite 100%

Example #3

% wt. of dissolvable Dissolvable region region calcium hypochlorite100%  % wt. of non- Non-dissolvable dissolvable region region magnesiumsilicate 80% lauric acid 20%

Example #4

% wt. of dissolvable Dissolvable region region calcium hypochlorite 100%% wt. of non- Non-dissolvable dissolvable region region mica 100%

Example #5

% wt. of dissolvable Dissolvable region region calcium hypochlorite100%  % wt. of non- Non-dissolvable dissolvable region regionpolypropylene mesh 40% plaster of Paris 60%

Example #6

% wt. of dissolvable Dissolvable region region calcium hypochlorite 100%% wt. of non- Non-dissolvable dissolvable region region magnesiumhydroxide 100%

Example #7

Dissolvable region % wt. of dissolvable region calcium hypochlorite100%  % wt. of non-dissolvable Non-dissolvable region region magnesiumhydroxide 90% palmitic acid 10%

Example #8

Dissolvable region % wt. of dissolvable region calcium hypochlorite 98%hydrophobic silica  2% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10%

Example #9

Dissolvable region % wt. of dissolvable region calcium hypochlorite 98%magnesium oxide  2% % wt. of non-dissolvable Non-dissolvable regionregion calcium sulfate 95% dimethicone  5%

Example #10

Dissolvable region % wt. of dissolvable region calcium hypochlorite 95%calcium sulfate  5% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region lauric acid 10% sodium bisulfate 90%

Example #11

Dissolvable region % wt. of dissolvable region calcium hypochlorite71.2% calcium sulfate  8.5% magnesium hydroxide 16.9% sodium carbonate 3.4% % wt. of non-dissolvable Non-dissolvable region region sodiumstearate  100%

Example #12

Dissolvable region % wt. of dissolvable region calcium hypochlorite 95% calcium stearate 2% calcium sulfate 3% % wt. of non-dissolvableNon-dissolvable region region magnesium stearate 100%  Third region %wt. of third region zinc stearate 5% sodium bisulfate 95% 

Example #13

Dissolvable region % wt. of dissolvable region calcium hypochlorite 100%% wt. of non-dissolvable Non-dissolvable region region magnesiumhydroxide 100% Third region % wt. of third region adipic acid  80%lauric acid  20%

Example #14

Dissolvable region % wt. of dissolvable region calcium hypochlorite 100%% wt. of non-dissolvable Non-dissolvable region region polypropylene100%

Example 15 includes an exemplary N-halogen compound as an antimicrobialsanitizing functional agent in the dissolvable region or layer.

Example #15

Dissolvable region % wt. of dissolvable region sodiumdichloroisocyanurate 100% % wt. of non-dissolvable Non-dissolvableregion region silicone 100%

Example 16 includes an exemplary quaternary ammonium compound as anantimicrobial sanitizing functional agent in the dissolvable region orlayer.

Example #16

Dissolvable region % wt. of dissolvable region N-alkylbenzyldimethylammonium chloride 80% sodium sulfate 20% % wt. of non-dissolvableNon-dissolvable region region palmitic acid 100% 

Example 17 includes an exemplary peroxide compound as an antimicrobialsanitizing functional agent in the dissolvable region or layer.

Example #17

Dissolvable region % wt. of dissolvable region sodium percarbonate 100%% wt. of non-dissolvable Non-dissolvable region region silicone 100%

Examples 18-22 include one or more surfactant functional agents in thedissolvable region or layer. Each of these examples includes a largefraction of sodium carbonate (e.g., about 75% to about 90% by weight)within the dissolvable region with the one or more surfactants, andwhich acts as a builder or carrier, which can increase the effectivenessof the surfactant. The sodium carbonate may also function as a softenerand/or a pH adjusting agent in the composition, as well as adjusting thesolubility of the surfactant functional agent.

Examples 19, 20, and 22 include 5% sodium polyacrylate within thedissolvable region. Inclusion of the sodium polyacrylate aids inpreventing scaling and/or precipitation of carbonate compounds (e.g.,calcium carbonate) as a result of ions (e.g., calcium and/or magnesiumions) available within the stream of tap water or elsewhere. The sodiumpolyacrylate also acts as a dispersant and dissolution aid, speeding upthe dissolution of the surfactant functional agent within thedissolvable region.

Example #18

Dissolvable region % wt. of dissolvable region sodium carbonate 79%sodium dodecyl sulfate 21% % wt. of non-dissolvable Non-dissolvableregion region polyethylene vinyl acetate 100% 

Example #19

Dissolvable region % wt. of dissolvable region sodium carbonate  88%sodium carboxymethyl cellulose 0.3% sodium xylene sulfonate 3.4% sodiumlinear alkylbenzene sulfonate 3.3% sodium polyacrylate(s)   5% % wt. ofnon-dissolvable Non-dissolvable region region polyethylene mesh  40%polypropylene  60%

Example #20

Dissolvable region % wt. of dissolvable region sodium carbonate  88%sodium carboxymethyl cellulose 0.3% sodium xylene sulfonate 3.4%secondary alkane sulfonate, sodium salt 3.3% sodium polyacrylate(s)   5%% wt. of non-dissolvable Non-dissolvable region region calcium sulfate 95% magnesium oxide   5%

Example #21

Dissolvable region % wt. of dissolvable region sodium carbonate 79%sodium dodecyl sulfate 21% % wt. of non-dissolvable Non-dissolvableregion region zinc oxide 100% 

Example #22

Dissolvable region % wt. of dissolvable region sodium carbonate 79%hydroxypropyl cellulose 0.7%  decylamine oxide 12% secondary alkanesulfonate, sodium salt 3.3%  sodium polyacrylate(s)  5% % wt. ofnon-dissolvable Non-dissolvable region region epoxy adhesive 100% 

Examples 23-28 include an exemplary flavorant functional agent in thedissolvable region or layer. In each of Examples 23-26, the flavorantcomprises sodium chloride, providing a salty flavor. Examples 27-28include sucrose as a flavorant, providing a sweet flavor. Other flavorscould alternatively be provided, and will be apparent to one of skill inthe art in light of the present disclosure.

Example #23

Dissolvable region % wt. of dissolvable region sodium chloride 100% %wt. of non-dissolvable Non-dissolvable region region Portland cement100%

Example #24

Dissolvable region % wt. of dissolvable region sodium chloride 100% %wt. of non-dissolvable Non-dissolvable region region carnauba wax 100%

Example #25

Dissolvable region % wt. of dissolvable region sodium chloride 100% %wt. of non-dissolvable Non-dissolvable region region calcium hydroxide100%

Example #26

Dissolvable region % wt. of dissolvable region sodium chloride 100% %wt. of non-dissolvable Non-dissolvable region region calcium phosphate100%

Example #27

Dissolvable region % wt. of dissolvable region sucrose 100%  % wt. ofnon-dissolvable Non-dissolvable region region fiberglass 40% silicone60%

Example #28

Dissolvable region % wt. of dissolvable region sucrose 100% % wt. ofnon-dissolvable Non-dissolvable region region cellulose 100%

Example 29 includes a fragrance functional agent in the dissolvableregion or layer. Example 29 further includes a large fraction of lauricacid (e.g., about 90% to about 98% by weight) within the dissolvableregion with the fragrance, which acts as a builder or carrier for thefragrance, and which can increase the effectiveness of the fragrance.Glycerin is also included as a carrier for the fragrance. For example, aliquid glycerin with fragrance dissolved in it may be deposited on thetalk and lauric acid solids to result in the dissolvable region. Thelauric acid may also function to adjust the solubility of the fragranceto control the rate of dissolution or entrainment of the fragrance intothe stream of water. The lauric acid may also provide anti-oxidantand/or antimicrobial properties (e.g., where the shaped composition isused as an aromatherapy shower wash).

Example #29

Dissolvable region % wt. of dissolvable region lauric acid 96.2%  talc2.9% glycerin 0.8% fragrance (citrus) 0.1% % wt. of non-dissolvableNon-dissolvable region region polyurethane 100% 

Examples 30-31 are additional hypochlorite antimicrobial sanitizingfunctional agent cylindrically shaped composition examples that wereformed with and without substantially non-dissolvable layers, and withdifferent diameter to height aspect ratios for the dissolvable layer ofthe shaped composition in order to demonstrate the effect of thesubstantially non-dissolvable layer and the aspect ratio on theuniformity of dissolution of the hypochlorite functional agent.

Example #30

Aspect Composition Dissolvable Non-dissolvable ratio label layer layer(diameter · Uniform (description) composition composition height⁻¹)dissolution? 30a (single calcium none 2.07 no layer, low hypochlorite,aspect ratio) 100% wt. 30b (single calcium none 4.83 yes layer, highhypochlorite, aspect ratio) 100% wt.

Example #31

Non- Aspect Composition Dissolvable dissolvable ratio label layer layer(diameter · Uniform (description) composition composition height⁻¹)dissolution? 31a (dual layer, calcium polyethylene 2.04 yes low aspectratio) hypochlorite, 100% wt. 31b (dual layer calcium polyethylene 4.83yes high aspect hypochlorite, ratio) 100% wt.

Dissolution rate data for Examples 30 and 31 are presented in FIGS.9-12. For example, FIG. 9 shows the dissolution rate data for Example 30a, a calcium hypochlorite dissolvable layer having an aspect ratio ofabout 2 with no non-dissolvable backing layer. As shown in FIG. 9, thedissolution rate shows undesirable deviation from uniformity,particularly after 50% of the calcium hypochlorite has dissolved. FIG.10 shows similar data for Example 30 b, which is similar to Example 30 abut with a higher aspect ratio, of almost 5. At this aspect ratio, evenwithout a non-dissolvable backing layer, the dissolution issubstantially uniform over the entire life of the dissolvable layer.

FIG. 11 shows similar data for Example 31 a, which was similar toExample 30 a, but which included a non-dissolvable backing layer. Thenon-dissolvable backing layer significantly improves the uniformity ofthe dissolution of the dissolvable layer, so as to only show deviationafter about 90% of the dissolvable region has been dissolved. FIG. 12shows similar data for Example 31 b, which was similar to Example 30 b,but with a non-dissolvable backing layer. Like FIG. 10, this examplealso showed substantially uniform dissolution over the entire life ofthe dissolvable layer.

Examples 32-36 are additional hypochlorite antimicrobial sanitizingshaped composition examples. Example 32-34 include a third region withsodium chloride that may act to adjust the solubility of thehypochlorite functional agent. Example 33 further includes a surfactantin the third region. Example 34 further includes a polyacrylate in thethird region. Example 35 includes a third region including a colorant,while Example 36 includes a third region including a fragrance.

Example #32

Dissolvable region % wt. of dissolvable region calcium hypochlorite 99%calcium stearate  1% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region Zeolite A 10% Sodium chloride 90%

Example #33

Dissolvable region % wt. of dissolvable region calcium hypochlorite 99%calcium stearate  1% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region Sodium lauryl sulfate 10% Sodium chloride 90%

Example #34

Dissolvable region % wt. of dissolvable region calcium hypochlorite 99%calcium stearate  1% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region Sodium polyacrylate 10% Sodium chloride 90%

Example #35

Dissolvable region % wt. of dissolvable region calcium hypochlorite 99%calcium stearate  1% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region Sodium sulfate 95% Calcium stearate  1% Ultramarine blue 4%

Example #36

Dissolvable region % wt. of dissolvable region calcium hypochlorite 99%calcium stearate  1% % wt. of non-dissolvable Non-dissolvable regionregion magnesium hydroxide 90% palmitic acid 10% Third region % wt. ofthird region Sodium sulfate 98% Calcium stearate  1% Fragrance  1%

One will appreciate in light of the disclosure herein that the presentinvention may be embodied in other specific forms without departing fromits spirit or essential characteristics. Thus, the described embodimentsare to be considered in all respects only as illustrative and notrestrictive. The scope of the invention is, therefore, indicated by theappended claims rather than by the foregoing description. All changesthat come within the meaning and range of equivalency of the claims areto be embraced within their scope.

1. A solid shaped composition for use in delivering a substantiallyuniform concentration of a hypochlorite anti-microbial sanitizing agentto a flowing stream of water, the shaped composition comprising: a firstregion comprising a hypochlorite salt selected from the group consistingof calcium hypochlorite, magnesium hypochlorite and mixtures thereof,the first region being dissolvable into a flowing stream of water; thefirst region being substantially cylindrical so as to include a topsurface, a bottom surface, and a peripheral surface; and a second regioncomprising a substantially non-dissolvable material, the second regionbeing adjacent to at least one of the top or bottom surface of the firstregion; and wherein the first region and the second region are noteffervescent; and wherein the first region and the second region containno sodium hypochlorite or lithium hypochlorite.
 2. The shapedcomposition as recited in claim 1, wherein the substantiallynon-dissolvable material of the second region is selected from the groupconsisting of a cementitious material, a polymer, an inorganic material,a fatty acid, a fatty acid salt, and mixtures thereof.
 3. The shapedcomposition as recited in claim 1, wherein the hypochlorite saltcomprises about 55% to 100% by weight of the first region.
 4. The shapedcomposition as recited in claim 1, wherein the hypochlorite saltcomprises about 60% to 100% by weight of the first region.
 5. The shapedcomposition as recited in claim 1, wherein the hypochlorite saltcomprises about 70% to 100% by weight of the first region.
 6. The shapedcomposition as recited in claim 2, wherein the substantiallynon-dissolvable material of the second region comprises a cementitiousmaterial selected from the group consisting of hydraulic cement,hydraulic cement blends, Pozzolan-lime cement, supersulfated cement,calcium aluminate cement, calcium sulfoaluminate cement, geopolymercement, magnesium oxychloride, magnesium oxysulfate, plaster of Paris,Portland cement, and mixtures thereof.
 7. The shaped composition asrecited in claim 2, wherein the substantially non-dissolvable materialof the second region comprises an inorganic material selected from thegroup consisting of hydroxide and oxide compounds of alkaline earthmetals, alkaline earth sulfates, alkaline earth phosphates, silicates,borate, aluminate, silica-aluminate, clays, zeolites including hydrates,mono, di and tribasic compounds, fiberglass, zinc oxide, and mixturesthereof.
 8. The shaped composition as recited in claim 7, wherein thehydroxide and oxide compounds of alkaline earth metals is selected fromthe group consisting of magnesium oxide, magnesium hydroxide, calciumhydroxide, calcium oxide, and mixtures thereof.
 9. The shapedcomposition as recited in claim 7, wherein the alkaline earth sulfatecomprises calcium sulfate.
 10. The shaped composition as recited inclaim 2, wherein the substantially non-dissolvable material of thesecond region comprises a fatty acid or fatty acid salt selected fromthe group consisting of stearic acid, palmitic acid, calcium stearate,magnesium stearate, sodium stearate, and combinations thereof.
 11. Theshaped composition as recited in claim 2, wherein the substantiallynon-dissolvable material of the second region comprises a polymerselected from the group consisting of waxes, resins, natural polymers,phenol resins, polyethylene vinyl acetate, polyolefins, polyamides,polyesters, cellulose, polymers formed from styrene block copolymersprecursors, polycaprolactone, fluoropolymers, silicone rubbers,polypyrrole, polyalkylsiloxanes, alkyl polyesters, polyvinyl chloride,urea-formaldehyde resins, polymethyl methacrylate, water-insolublepolyacrylate, acrylonitrile butadiene styrene, polystyrene, epoxyadhesives, nylon, polyfluorocarbons, melamine-formaldehyde,polyurethane, polycarbonate, polyimide resins, hydrogels, silicones,polyester, polyethylene, polypropylene, and combinations thereof. 12.The shaped composition as recited in claim 1, wherein the first regionfurther comprises a solubility adjusting agent selected from the groupconsisting of silica, hydrophobic silica, hydrophobic clay, phosphates,chlorides, polysiloxane compounds, sulfates, calcium sulfate, sodiumsulfate, calcium hydroxide, magnesium hydroxide, waxes, resins,cellulose, cellulosic materials, polyolefins, polyethylene, oxidizedpolyethylene, calcium stearate, magnesium stearate, sodium stearate,zinc stearate, fatty acids, silicone, polydimethyl siloxane,dimethicone, cyclodimethicone, hexamethyldisiloxane, magnesium aluminumsilicate, sodium magnesium silicate, calcium carbonate, butyl stearate,calcium silicate, dolomite, magnesium carbonate, sodium carbonate,magnesium oxide, magnesium oxide silicate, talc, magnesium sulfate,mineral oil, castor oil, and combinations thereof.
 13. The shapedcomposition as recited in claim 1, wherein the shaped compositionfurther comprises a third region that is dissolvable and that iscompositionally different from the dissolvable region, the third regionbeing separated from the dissolvable region by the non-dissolvableregion, the third region comprising a material selected from the groupconsisting of an organic acid, an inorganic acid, a carboxylic acid, adicarboxylic acid, a phosphoric acid, a phosphonic acid, a sulfuricacid, a sulfonic acid, a saturated fatty acid, an unsaturated fattyacid, an acid salt, and combinations thereof.
 14. A solid cylindricallyshaped composition for use in delivering a substantially uniformconcentration of a hypochlorite anti-microbial sanitizing agent to aflowing stream of water, the shaped composition comprising: a firstlayer consisting essentially of a hypochlorite salt selected from thegroup consisting of calcium hypochlorite, magnesium hypochlorite andmixtures thereof, the first layer being dissolvable into a flowingstream of water; the first layer being substantially cylindrical so asto include a top surface, a bottom surface, and a peripheral surface; asecond layer consisting essentially of a substantially non-dissolvablematerial selected from the group consisting of cementitious materials,polymers, inorganic materials, fatty acids, fatty acid salts, andmixtures thereof; the second layer being adjacent to the bottom surfaceof the first layer so as to cover the bottom surface of the first layer;the second layer also being substantially cylindrical and having adiameter substantially equal to that of the first layer so that anexterior peripheral surface of both the first layer and adjacent secondlayer are substantially flush with one another; and wherein the firstlayer and the second layer are not effervescent.
 15. The shapedcomposition as recited in claim 14, wherein the substantiallynon-dissolvable material of the second region is selected from the groupconsisting of a cementitious material, a polymer, an inorganic material,a fatty acid, a fatty acid salt, and mixtures thereof.
 16. The shapedcomposition as recited in claim 14, wherein the hypochlorite saltcomprises about 55% to 100% by weight of the first region.
 17. Theshaped composition as recited in claim 14, wherein the hypochlorite saltcomprises about 60% to 100% by weight of the first region.
 18. Theshaped composition as recited in claim 14, wherein the hypochlorite saltcomprises about 70% to 100% by weight of the first region.
 19. Theshaped composition as recited in claim 14, wherein: the shapedcomposition further comprises a third region that is dissolvable andthat is compositionally different from the dissolvable region, the thirdregion being separated from the dissolvable region by thenon-dissolvable region; and the third region comprises a materialselected from the group consisting of an organic acid, an inorganicacid, a carboxylic acid, a dicarboxylic acid, a phosphoric acid, aphosphonic acid, a sulfuric acid, a sulfonic acid, a saturated fattyacid, an unsaturated fatty acid, an acid salt, and combinations thereof.20. The shaped composition as recited in claim 14, wherein thesubstantially non-dissolvable material of the second region comprises apolymer selected from the group consisting of waxes, resins, naturalpolymers, phenol resins, polyethylene vinyl acetate, polyolefins,polyamides, polyesters, cellulose, polymers formed from styrene blockcopolymers precursors, polycaprolactone, fluoropolymers, siliconerubbers, polypyrrole, polyalkylsiloxanes, alkyl polyesters, polyvinylchloride, urea-formaldehyde resins, polymethyl methacrylate,water-insoluble polyacrylate, acrylonitrile butadiene styrene,polystyrene, epoxy adhesives, nylon, polyfluorocarbons,melamine-formaldehyde, polyurethane, polycarbonate, polyimide resins,hydrogels, silicones, polyester, polyethylene, polypropylene, andcombinations thereof.